workshop manual - Lombardini i

WORKSHOP MANUAL

9 LD Engine Series

cod. ED0053022860

9 LD Engine Series

PREFACE

- Every attempt has been made to present within this service manual, accurate and up to date technical information.

However, development on the

LOMBARDINI

series is continuous.

Therefore, the information within this manual is subject to change without notice and without obligation.

- The information contained within this service manual is the sole property of

LOMBARDINI

.

As such, no reproduction or replication in whole or part is allowed without the express written permission of

LOM-

BARDINI

.

Information presented within this manual assumes the following:

1 - The person or people performing service work on

LOMBARDINI

series engines is properly trained and equipped to safely and professionally perform the subject operation;

2 - The person or people performing service work on

LOMBARDINI

series engines possesses adequate hand and

LOMBARDINI

special tools to safely and professionally perform the subject service operation;

3 - The person or people performing service work on

LOMBARDINI

series engines has read the pertinent information regarding the subject service operations and fully understands the operation at hand.

-

This manual was written by the manufacturer to provide technical and operating information to authorised

LOM-

BARDINI

after-sales service centres to carry out assembly, disassembly, overhauling, replacement and tuning operations.

-

As well as employing good operating techniques and observing the right timing for operations, operators must read the information very carefully and comply with it scrupulously.

-

Time spent reading this information will help to prevent health and safety risks and financial damage.

Written information is accompanied by illustrations in order to facilitate your understanding of every step of the operating phases.

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REGISTRATION OF MODIFICATIONS TO THE DOCUMENT

Any modifications to this document must be registered by the drafting body, by completing the following table.

Drafting body

CUSE/ATLO

Document code

Model

ED0053022860 50494

Edition

Revision

3

Issue date

06-88

Review date

01.09.2014

Endorsed

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CHAPTER INDEX

-

This manual contains pertinent information regarding the repair of LOMBARDINI air-cooled, direct injection Diesel engines type

9 LD 625-2 - 625-2 EPA - 626-2 - 626-2 NR

.

TABLE OF CONTENTS

1 GENERAL REMARKS AND SAFETY INFORMATION ______________________________________ 9-11

California Proposition 65 WARNING ..................................................................................................................................11

General safety during operationg phases ..........................................................................................................................11

General service manual notes ............................................................................................................................................ 9

Glossary and terminology ................................................................................................................................................... 9

Regulations for lifting the engine ......................................................................................................................................... 9

Safety and environmental impact .......................................................................................................................................11

Safety regulations ............................................................................................................................................................. 10

Warranty certificate ............................................................................................................................................................. 9

2 TECHNICAL INFORMATION _________________________________________________________ 12-21

Approval data .................................................................................................................................................................... 14

Main components .............................................................................................................................................................. 15

Manufacturer and engine identification ............................................................................................................................. 14

Overall dimension ............................................................................................................................................................. 20

Performance diagram ................................................................................................................................................... 18-19

Table of likely anomalies and their symptoms ................................................................................................................... 12

Technical specifications ................................................................................................................................................ 16-17

Trouble shooting........................................................................................................................................................... 12-13

3 MAINTENANCE - RECOMMENDED OIL TYPE - REFILLING _____________________________ 22-25

ACEA Regulations - Sequences ....................................................................................................................................... 23

API / MIL Sequences ....................................................................................................................................................... 23

Extraordinary maintenance ............................................................................................................................................... 22

Fuel recommendations ...................................................................................................................................................... 25

International specifications ................................................................................................................................................ 23

Lubricant ........................................................................................................................................................................... 23

Ordinary maintenance ...................................................................................................................................................... 22

Prescribed lubricant .......................................................................................................................................................... 24

Routine engine maintenance ............................................................................................................................................ 22

SAE Classification ............................................................................................................................................................ 23

4 DISASSEMBLY / REASSEMBLY ______________________________________________________ 26-51

Air cleaner ......................................................................................................................................................................... 26

Camshaft ........................................................................................................................................................................... 45

Camshaft end play ............................................................................................................................................................ 46

Camshaft timing ................................................................................................................................................................ 46

Center main bearing support, locating screw. ................................................................................................................... 42

Checking main journals and crank pins ............................................................................................................................ 43

Clearance between main journals/crank pins and connecting rod bearings ..................................................................... 44

Clogging indicator ............................................................................................................................................................. 28

Compression release ....................................................................................................................................................... 32

Connecting rod .................................................................................................................................................................. 39

Connecting rod alignment ................................................................................................................................................. 40

Connecting rod big end bearing ........................................................................................................................................ 40

Connecting rod small end bushing .................................................................................................................................... 40

Connecting rod weight ...................................................................................................................................................... 40

Cooling fan ........................................................................................................................................................................ 30

Crankshaft ......................................................................................................................................................................... 42

Crankshaft center main bearing support ........................................................................................................................... 42

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Chapter index

Crankshaft end play .......................................................................................................................................................... 45

Crankshaft journal radius .................................................................................................................................................. 43

Crankshaft lubrication ducts .............................................................................................................................................. 42

Crankshaft removal ........................................................................................................................................................... 42

Crankshaft timing gear ...................................................................................................................................................... 41

Cylinder ............................................................................................................................................................................. 36

Cylinder head .................................................................................................................................................................... 33

Dimensions and clearance between guides and valves ................................................................................................... 35

Dimensions of camshaft journals and housings ................................................................................................................ 45

Dry air cleaner ................................................................................................................................................................... 27

Dry air cleaner, Donaldson type ........................................................................................................................................ 27

Electronic speed governor ................................................................................................................................................ 49

Exhaust manifold ............................................................................................................................................................... 28

External alternator blower control belt - Disassembly ....................................................................................................... 29

External alternator blower control belt - Reassembly ........................................................................................................ 29

External alternator blower control belt – Tension check .................................................................................................... 29

External alternator control belt .......................................................................................................................................... 29

Flywheel ............................................................................................................................................................................ 31

Fuel tank ........................................................................................................................................................................... 29

Governor springs with rocker arm system ......................................................................................................................... 49

Governor springs with single-spring system ..................................................................................................................... 49

Head seal thickness .......................................................................................................................................................... 39

How to measure camshaft journals and housings ............................................................................................................ 45

How to measure intake/exhaust cam height ..................................................................................................................... 46

How to measure main bearing inside diameter ................................................................................................................. 43

Hub .................................................................................................................................................................................... 30

Hydraulic pump ................................................................................................................................................................. 47

Hydraulic pump components (1 P) .................................................................................................................................... 48

Hydraulic pump p.t.o ......................................................................................................................................................... 47

Injector .............................................................................................................................................................................. 32

Injector for EPA and 97/68 CE engines ............................................................................................................................. 33

Injector projection .............................................................................................................................................................. 33

Intake manifold .................................................................................................................................................................. 28

Internal alternator .............................................................................................................................................................. 30

Main bearing and connecting rod big end bearing inside diameter ................................................................................... 44

Main bearing housings ...................................................................................................................................................... 44

Main bearing support, flywheeI side .................................................................................................................................. 41

Main bearing support, gear side ........................................................................................................................................ 41

Main bearing supports ....................................................................................................................................................... 41

Main bearíng supports - Dimensions ................................................................................................................................ 44

Main journal and crank pin diameter ................................................................................................................................. 43

Manifolds, intake/exhaust .................................................................................................................................................. 28

Mechanical speed governor .............................................................................................................................................. 48

Mechanical speed governor components ......................................................................................................................... 48

Oil vapour separator ......................................................................................................................................................... 28

Oil-bath air cleaner ............................................................................................................................................................ 26

Piston ................................................................................................................................................................................ 37

Piston - Refitting ................................................................................................................................................................ 39

Piston clearance ................................................................................................................................................................ 39

Piston rings - End gaps (mm) ............................................................................................................................................ 38

Piston rings - Fitting sequence .......................................................................................................................................... 38

Piston weight ..................................................................................................................................................................... 38

Pistons rings - Clearance between grooves (mm) ............................................................................................................ 38

Pulley guard - Shroud - Side plates .................................................................................................................................. 30

Pushrod tube ..................................................................................................................................................................... 36

Recommendations for disassembling and assembling ..................................................................................................... 26

Recommendations for overhauls and tuning ..................................................................................................................... 26

Rocker arm assembly ....................................................................................................................................................... 32

Rocker arms ...................................................................................................................................................................... 31

Shroud support (Gear cover plate) .................................................................................................................................... 31

Speed governor wiring diagram ........................................................................................................................................ 50

Table “Clearance between main bearings and main bearing housings” ........................................................................... 45

Table “Piston and cylinder types and sizes" ...................................................................................................................... 37

Valve / Rocker arm clearance ........................................................................................................................................... 31

Valve guide insertion ......................................................................................................................................................... 35

Valve guides and valve guide housings ............................................................................................................................ 35

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Chapter index

-

Valve material .................................................................................................................................................................... 34

Valve seat grinding ............................................................................................................................................................ 36

Valve seats and housings ................................................................................................................................................. 36

Valve springs ..................................................................................................................................................................... 34

Valve stem sealing rings - Reassembly ........................................................................................................................... 34

Valve timing - Angles ......................................................................................................................................................... 47

Valve timing check ............................................................................................................................................................ 47

Valve timing without considering timing marks .................................................................................................................. 46

Valves ................................................................................................................................................................................ 34

5 LUBRICATION SYSTEM ____________________________________________________________ 52-55

Lubrication system and breather recirculation system ...................................................................................................... 52

Lubrication system with oil radiator circuit ......................................................................................................................... 53

Oil filter cartridge (external) ............................................................................................................................................... 54

Oil pressure check ............................................................................................................................................................ 55

Oil pressure curve with engine at full speed ..................................................................................................................... 55

Oil pressure curve with engine at idle speed .................................................................................................................... 55

Oil pressure relief valve ..................................................................................................................................................... 54

Oil pump ............................................................................................................................................................................ 53

Oil radiator ......................................................................................................................................................................... 55

Standard lubrication system circuit ................................................................................................................................... 52

6 FUEL SYSTEM ____________________________________________________________________ 56-65

Fuel feeding / injection circuit with external fuel filter ........................................................................................................ 56

Fuel feeding / injection circuit with external fuel filter and double solenoid valve ............................................................. 56

Fuel feeding / injection circuit with external fuel filter and QSD (Quick Stop System) ...................................................... 57

Fuel feeding / injection circuit with fuel filter inside the fuel tank ....................................................................................... 56

Fuel feeding / injection circuit with fuel filter inside the fuel tank and double solenoid valve ............................................ 56

Fuel feeding /injection circuit ............................................................................................................................................. 56

Fuel feeding pump components ........................................................................................................................................ 58

Fuel filter ........................................................................................................................................................................... 57

Fuel filter (inside fuel tank) ................................................................................................................................................ 57

Fuel filter, external ............................................................................................................................................................. 57

Fuel lift pump ..................................................................................................................................................................... 57

How to check injection pump delivery valve sealing ......................................................................................................... 60

How to check plunger and barrel for internal leakage ....................................................................................................... 59

How to mount injection pump on the engine ..................................................................................................................... 61

How to reassemble injection pump components ............................................................................................................... 61

Injection advance adjustment ............................................................................................................................................ 63

Injection pump ................................................................................................................................................................... 58

Injection pump for EPA engines ........................................................................................................................................ 59

Injection pump for Standard and 97/68 CE engines ......................................................................................................... 58

Injection pump/mechanical speed governor timing ........................................................................................................... 62

Injection static advance adjustment .................................................................................................................................. 62

Injector .............................................................................................................................................................................. 64

Injector setting ................................................................................................................................................................... 65

Piston fuel lift pump (on request) ...................................................................................................................................... 58

Plunger and Barrel Assembly ............................................................................................................................................ 59

Size P injector, for 97/68 CE and EPA engines ................................................................................................................. 65

Size P nozzle, for 97/68 CE and EPA engines .................................................................................................................. 65

Size S Injector, only for standard engines ......................................................................................................................... 64

Size S Nozzle, only for standard engines ......................................................................................................................... 64

(Static) injection timing ...................................................................................................................................................... 62

Table “Conversion for establishing advance” .................................................................................................................... 63

Test data for injection pump delivery ................................................................................................................................. 60

7 ELECTRIC SYSTEM ________________________________________________________________ 66-75

Alternator ......................................................................................................................................................................... 67

Alternator - 12 V, 14 A ..................................................................................................................................................... 68

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Chapter index

Alternator - 12 V, 18A ........................................................................................................................................................ 67

Alternator - 24 V, 6 A ....................................................................................................................................................... 67

Alternator battery charger curve - 24 V, 6 A ...................................................................................................................... 68

Alternator battery charger curve - external, 12 V, 33 A...................................................................................................... 69

Alternator battery charger curve (12 V, 18 A) .................................................................................................................... 67

Alternator battery charger curve standard - 12 V, 14 A .................................................................................................... 68

Alternator, external - 12 V, 33 A ......................................................................................................................................... 69

Characteristic curves for starting motor type Bosch - 12 V, 1.7 kW .................................................................................. 72

Characteristic curves of the 24 V 1.6 kW starting motor ................................................................................................... 73

Checking for cable continuity ............................................................................................................................................ 69

Direct stop electromagnet ................................................................................................................................................. 75

Direct stop electromagnets ............................................................................................................................................... 74

Electric starting layout with internal alternator ................................................................................................................... 66

Electrical starting layout with external alternator ............................................................................................................... 66

How to check voltage regulator for proper operation ........................................................................................................ 70

Magnetization checking tool .............................................................................................................................................. 68

Pre-heating glow plug ....................................................................................................................................................... 74

Reverse electromagnet – FIRE version ............................................................................................................................ 74

Starting motor .................................................................................................................................................................... 72

Starting motor type Bosch DW (R) 12 V, 1.7 kW............................................................................................................... 73

Voltage regulator ............................................................................................................................................................... 70

Voltage regulator - 12 V, 30 A ........................................................................................................................................... 71

Voltage regulator - 12V, 26A, with “W” terminal ............................................................................................................... 71

Voltage regulator - 12V, 30A, with “W” terminal ............................................................................................................... 71

8 SETTINGS _______________________________________________________________________ 76-79

Full speed setting in no-load conditions (standard) ........................................................................................................... 76

Idling speed setting in no-load conditions ......................................................................................................................... 76

Injection pump delivery setting .......................................................................................................................................... 76

Injection pump delivery setting with dynamometric brake ................................................................................................. 77

lnjection pump delivery limiting and extra fuel device ....................................................................................................... 76

lnjection pump delivery setting without dynamometric brake ............................................................................................ 77

Required settings (as most commonly applies) ................................................................................................................ 78

Setting the stop limit stop .................................................................................................................................................. 78

Speed adjustments ........................................................................................................................................................... 76

9 STORAGE ________________________________________________________________________ 80-81

Engine storage .................................................................................................................................................................. 80

Preparing the engine for operation after protective treatment ........................................................................................... 81

Protective treatment .......................................................................................................................................................... 80

10 TORQUE SPECIFICATIONS AND USE OF SEALANT ____________________________________ 82-84

Table of tightening torques for standard screws (coarse thread) ...................................................................................... 84

Table of tightening torques for standard screws (fine thread) ........................................................................................... 84

Table of tightening torques for the main components .................................................................................................. 82-83

11 SPECIAL TOOLS _____________________________________________________________________85

Special tools and equipment for maintenance .................................................................................................................. 85

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GENERAL REMARKS AND SAFETY INFORMATION

1

WARRANTY CERTIFICATE

-

-

-

-

-

-

-

- The products manufactured by Lombardini Srl are warranted to be free from conformity defects for a period of 24 months from the date of delivery to the first end user.

- For engines fitted to stationary equipment, working at constant load and at constant and/or slightly variable speed within the setting limits, the warranty covers a period up to a limit of 2000 working hours, if the above mentioned period (24 months) is not expired.

- If no hour-meter is fitted , 12 working hours per calendar day will be considered.

- For what concerns the parts subject to wear and deterioration (injection/feeding system, electrical system, cooling system, sealing parts, non-metallic pipes, belts) warranty covers a maximum limit of 2000 working hours, if the above mentioned period

(24 months) is not expired.

- For correct maintenance and replacement of these parts, it is necessary to follow the instructions reported in the documentation supplied with each engine.

- To ensure the engine warranty is valid, the engine installation, considering the product technical features, must be carried out by qualified personnel only.

- The list of the Lombardini authorized dealers is reported in the “Service” booklet, supplied with each engine.

- Special applications involving considerable modifications to the cooling/lubricating system (for ex.: dry oil sump), filtering system, turbo-charged models, will require special written warranty agreements.

- Within the above stated periods Lombardini Srl directly or through its authorized network will repair and/or replace free of charge any own part or component that, upon examination by Lombardini or by an authorized Lombardini agent, is found to be defective in conformity, workmanship or materials.

- Any other responsibility/obligation for different expenses, damages and direct/indirect losses deriving from the engine use or from both the total or partial impossibility of use, is excluded.

- The repair or replacement of any component will not extend or renew the warranty period.

Lombardini warranty obligations here above described will be cancelled if:

Lombardini engines are not correctly installed and as a consequence the correct functional parameters are not respected and altered.

Lombardini engines are not used according to the instructions reported in the “Use and Maintenance” booklet supplied with each engine.

Any seal affixed to the engine by Lombardini has been tampered with or removed.

Spare parts used are not original Lombardini.

Feeding and injection systems are damaged by unauthorized or poor quality fuel types.

Electrical system failure is due to components, connected to this system, which are not supplied or installed by Lombardini.

Engines have been disassembled, repaired or altered by any part other than an authorized Lombardini agent.

- Following expiration of the above stated warranty periods and working hours, Lombardini will have no further responsibility for warranty and will consider its here above mentioned obligations for warranty complete.

- Any warranty request related to a non-conformity of the product must be addressed to the Lombardini Srl service agents.

GENERAL SERVICE MANUAL NOTES

1 - Use only genuine Lombardini repair parts.

Failure to use genuine Lombardini parts could result in sub-standard performance and low longevity.

2 - All data presented are in metric format. That is, dimensions are presented in millimeters (mm), torque is presented in

Newton-meters (Nm), weight is presented in kilograms (Kg), volume is presented in liters or cubic centimeters (cc) and pressure is presented in barometric units (bar).

GLOSSARY AND TERMINOLOGY

For clarity, here are the definitions of a number of terms used recurrently in the manual.

- Cylinder number one:

is the timing belt side piston .

- Rotation direction:

anticlockwise «viewed from the flywheel side of the engine».

Regulations for lifting the engine

- Before removing the engine from the vehicle on which it is installed, disconnect the power supply, detach the fuel and coolant supply, and all connections including the mechanical ones.

- Attach the engine to a suitable lifting device (lifting beam).

- To move the engine simultaneously use the eyebolts installed, these lifting points are not suitable for the entire machine, then use the eyebolts installed by the manufacturer.

- Before lifting, make sure the weight is correctly balanced by checking its barycentre.

- Close all engine openings accurately (exhaust, intake, etc.), then wash the outside and dry with a jet of compressed air.

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General remarks and safety information

This manual contains safety precautions which are explained below.

WARNING

Warning is used to indicate the presence of a hazard that can cause severe personal injury, death, or substantial property damage if the warning is ignored.

CAUTION

Caution is used to indicate the presence of a hazard that will or can cause minor personal injury or property damage if the caution is ignored.

IMPORTANT

This indicates particularly important technical information that should not be ignored.

Safety regulation

.

.

GENERAL NOTES

prescribed health and safety requirements. Any use of the machine other than that described cannot be considered as complying with its intended purpose as specified by

Lombardini

, which therefore declines all responsibility for accidents caused by such operations.

.

The following instructions are intended for the user of the machine in order to reduce or eliminate risks, especially those concerning the operation and standard maintenance of the engine.

.

The user should read these instructions carefully and get to know the operations described. By not doing so he may place at risk his own health and safety and that of anyone else in the vicinity of the machine.

.

The engine may be used or mounted on a machine only by personnel suitably trained in its operation and aware of the dangers involved. This is particularly true for standard and, above all, special maintenance work. For special maintenance contact personnel trained specifically by

Lombardini

. This work should be carried out in accordance with existing literature.

.

Lombardini

declines all responsibility for accidents or for failure to comply with the requirements of law if changes are made to the engine’s functional parameters or to the fuel flow rate adjustments and speed of rotation, if seals are removed, or if parts not described in the operating and maintenance manual are removed and reassembled by unauthorized personnel.

WARNING

.

In addition to all other machine specifications, ensure that the engine is in a near horizontal position when starting. lf starting manually, ensure that the necessary operations can be performed without any risk of striking against walls or dangerous objects. Rope starting (except for recoil rope starting) is not permitted even in emergencies.

.

Check that the machine is stable so that there is no risk of it overturning.

Get to know the engine speed adjustment and machine stop operations.

Do not start the machine in closed or poorly ventilated environments. The internal combustion process generates carbon monoxide, an odourless and highly toxic gas, so spending too long a time in an environment where the engine discharges its exhaust products freely can lead to loss of consciousness and even death.

.

The engine may not be used in environments containing flammable materials, explosive atmospheres or easily combustible powders, unless adequate and specific precautions have been taken and are clearly stated and certified for the machine.

.

To prevent the risk of fire, keep the machine at a distance of at least one metre from buildings or other machines.

.

Children and animals must be kept at a sufficient distance from the machine to prevent any danger resulting from its operation.

.

Fuel is flammable, so the tank must be filled only when the engine is turned off. Dry carefully any fuel that may have spilled, remove the fuel container and any cloths soaked in fuel or oil, check that any sound-absorbing panels made of porous material are not soaked with fuel or oil, and make sure that the ground on which the machine is located has not absorbed fuel or oil.

.

Before starting, remove any tools that have been used for carrying out maintenance work to the engine and/or the machine and check that any guards removed have been replaced. In cold climates it is possible to mix kerosene with the diesel fuel to make the engine easier to start. The liquids must be mixed in the tank by pouring in first the kerosene and then the diesel fuel. Consult

Lombardini

technical office for mixture proportions. Petrol may not be used because of the risk of it forming flammable vapours.

.

During operation the surface of the engine reaches temperatures that may be dangerous. Avoid in particular all contact with the exhaust system.

.

The liquid cooling circuit is under pressure. Do not carry out any checks before the engine has cooled down, and even then open the radiator cap or the expansion tank cautiously.

Wear protective clothing and glasses. lf there is an electric fan, do not approach the engine while it is still hot as the fan may come on even when the engine is not running. Clean the cooling system with the engine turned off.

.

While cleaning the oil bath air filter, check that the oil is disposed of in such a way as not to harm the environment.

Any filtering sponges in the oil bath air filter should not be soaked with oil. The cyclone pre-filter cup must not be filled with oil.

.

Since the oil must be emptied out while the engine is still hot

(approx. 80°C), particular care should be taken in order to avoid burns. In any case make sure that oil does not come into contact with your skin because of the health hazards involved.

.

Fuel vapours are highly toxic, so fill up only in the open air or in well ventilated environments.

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General remarks and safety information

1

.

During operations which involve access to moving parts of the engine and/or removal of the rotary guards, disconnect and insulate the positive cable of the battery so as to prevent accidental short circuits and activation of the starter motor.

.

Check the belt tension only when the engine is turned off.

IMPORTANT

.

To start the engine follow the specific instructions provided in the engine and/or machine operating manual. Do not use auxiliary starting devices not originally installed on the machine (e.g. Startpilot systems which utilise ether etc.)

.

Before carrying out any work on the engine, turn it off and allow it to cool down. Do not perform any operation while the engine is running.

.

Check that the discharged oil, the oil filter and the oil contained in the oil filter are disposed of in such a way as not to harm the environment.

.

Close the fuel tank filler cap carefully after each fílling operation. Do not fill the tank right up to the top, but leave sufficient space to allow for any expansion of the fuel.

.

Do not smoke or use naked flames while filling.

.

Take care when removing the oil filter as it may be hot.

.

The operations of checking, filling up and replacing the cooling liquid must be carried out with the engine turned off and cold.

Take particular care if liquids containing nitrites are mixed with others not containing these compounds as this may give rise to the formation of nitrosamines which are a health hazard.

The cooling liquid is polluting, so dispose of in a manner that does not damage the environment.

.

In order to move the engine simultaneously use the eyebolts fitted for this purpose by

Lombardini

. These lifting points are however not suitable for the entire machine, so in this case use the eyebolts fitted by the manufacturer.

California Proposition 65

WARNING

Engine exhaust from this product contains chemicals known to the

State of California to cause cancer, birth defects, or other reproductive harm.

GENERAL SAFETY DURING OPERATING PHASES

– The procedures contained in this manual have been tested and selected by the manufacturer’s technical experts, and hence are to be recognised as authorised operating methods.

– A number of procedures must be carried out with the aid of equipment and tools that simplify and improve the timing of operations.

– All tools must be in good working condition so that engine components are not damaged and that operations are carried out properly and safely.

It is important to wear the personal safety devices prescribed by work safety laws and also by the standards of this manual.

– Holes must be lined up methodically and with the aid of suitable equipment. Do not use your fingers to carry out this operation to avoid the risk of amputation.

– Some phases may require the assistance of more than one operator. If so, it is important to inform and train them regarding the type of activity they will be performing in order to prevent risks to the health and safety of all persons involved.

– Do not use flammable liquids (petrol, diesel, etc.) to degrease or wash components. Use special products.

– Use the oils and greases recommended by the manufacturer.

Do not mix different brands or combine oils with different characteristics.

– Discontinue use of the engine if any irregularities arise, particularly in the case of unusual vibrations.

– Do not tamper with any devices to alter the level of performance guaranteed by the manufacturer.

SAFETY AND ENVIRONMENTAL IMPACT

Every organisation has a duty to implement procedures to identify, assess and monitor the influence of its own activities

(products, services, etc.) on the environment.

Procedures for identifying the extent of the impact on the environment must consider the following factors:

-

Liquid waste

-

Waste management

-

Soil contamination

-

-

-

Atmospheric emissions

Use of raw materials and natural resources

Regulations and directives regarding environmental impact

In order to minimise the impact on the environment, the manufacturer now provides a number of indications to be followed by all persons handling the engine, for any reason, during its expected lifetime.

-

All packaging components must be disposed of in accordance with the laws of the country in which disposal is taking place.

-

Keep the fuel and engine control systems and the exhaust pipes in efficient working order to limit environmental and noise pollution.

-

When discontinuing use of the engine, select all components according to their chemical characteristics and dispose of them separately.

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TECHNICAL INFORMATION

TROUBLE SHOOTING

THE ENGINE MUST BE STOPPED IMMEDIATELY WHEN:

1)

- The engine rpms suddenly increase and decrease;

2)

- A sudden and unusual noise is heard;

3)

- The colour of the exhaust fumes suddenly darkens;

4)

- The oil pressure indicator light turns on while running.

TABLE OF LIKELY ANOMALIES AND THEIR SYMPTOMS

The following table contains the possible causes of some failures which may occur during operation.

Always perform these simple checks before removing or replacing any part.

PROBLEM

POSSIBLE CAUSE

Obstructed fuel line

Fuel filter clogged

Air or water leaks in fuel system

The tank cap vent hole is clogged

No fuel

Faulty fuel feeding pump

Extra fuel control level sticking

Clogged air filter

COOLING CIRCUIT

Cooling circuit clogged

Incorrect governor linkage adjustment

Governor spring broken or unhooked

Low idle speed

Rings worn or sticking

Worn cylinder

Worn main con rod-rocker arm bearings

Badly sealed intake valve

Head tightening nuts loose

Damaged cylinder head gasket

Excessive valve-rocker arm clearance

No clearance between valves and rocker arms

Valves sticking or damaged

Defective timing system

Bent rods

Crankshaft not turning freely

Engine does not start Engine starts but stops Non-uniform speed Oil preassure too low

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Excessive oil consumption High noise level

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POSSIBLE CAUSE

Damaged, blocked or dirty injector

Injection pump valve damaged

Injector not adjusted

Hardened pump control rod

Broken or loose supplementary start-up spring

Worn or damaged pumping element

Incorrect tuning of injection components

(delivery balancing advance)

Extra fuel control level sticking

Oil level too high

Oil level low

Oil pressure valve blocked or dirty

Oil pressure regulator not adjusted

Worm oil pump

Oil sump suction line clogged

Faulty pressure gauge or pressure switch

Blocked draining pipe

ELECTRIC SYSTEM

Discharged battery

Cable connection uncertain or incorrect

Faulty starting switch

Faulty starting motor

Excessive idle operation

Incomplete run-in

Overloaded engine

Non-conforming engine oil

Engine does not start

Engine starts but stops

PROBLEM

Technical information

2

Inadequate performance

High noise level

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Technical information

MANUFACTURER AND ENGINE IDENTIFICATION

B A

C F

D

The identification plate shown in the figure can be found directly on the engine.

It contains the following information:

A)

Manufacturer’s identity

B)

Engine type

C)

Engine serial number

D)

Maximum operating speed

E)

Number of the customer version (form K)

F)

Approval data

E

Approval data

The approval reference directives EC are on the engine identification plate.

6

- 14 -

2

4

6

1

3

5

7

The data plate for EPA Standards is applied on the air intake cowling.

It contains the following information:

1)

Current year

2)

Engine displacement

3)

Rated power, measured in kW

4)

EPA family ID

5)

Injection timing

6)

Injection opening preassure

7)

Valve clearance

5

1

3

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MAIN COMPONENTS

1

2 3

4

Components:

1)

Fuel tank

2)

Injectors

3)

Air cleaner

4)

Starting motor

5)

Oil filter

6)

Rocker arm cover

5

Technical information

2

6

12

7

8

9

7)

Oil dipstick

8)

Throttle and stop controls

9)

Oil drain plug

10)

Fuel feeding pump

11)

Flywheel

12)

Injection pump

10

11

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Technical information

TECHINICAL SPECIFICATIONS

9 LD engine type

Operating cycle

Cylinders

Bore x stroke

Displacements

Compression rate

Intake

Cooling

Crankshaft rotation

Combustion sequence

Timing system

Valves

Shaft

Tappets

Fuel injection

Dry weight of engine

Maximum tilt while operating

Maximum tilt while operating

Combustion air volume at 3000 r.p.m.

Cooling air volume at 3000 r.p.m.

Maximum operating speed

Maximum power

Maximum torque*

Axial load allowed on crankshaft

Specific fuel onsumption

Oil consumption

625-2

625/626-2

NR CE

625-2

EPA

GENERAL DETAILS

Four-stroke diesel n° mm cm

3

95x88

1248

2 in line

95x88

1248

95x88

1248

17.5:1 20.0:1 21.0:1

Oil bath air cleaner with cyclonic prefilter or dry air cleaner

Air (fan integral to the flywheel)

Counter-clockwise (from flywheel side)

Driving shaft degrees n°

180°

Rods and rocker arms

2 per cylinder

Kg

Side camshaft in the crankcase

Mechanic

Direct

110 110

Momentary

Up to 1 hour l/min l/min

35°

25°

1600

26300

35°

25°

1600

26300

110

35°

25°

1600

26300

POWER AND TORQUE

r.p.m.

N (80/1269/CEE) ISO 1585

NB ISO 3046 IFN

NA ISO 3046 ICXN kW/CV

Nm/Kgm

Kg

CONSUMPTION AT MAXIMUM POWER

g/kWh - g/CV1h

Kg/h

3000

20.7/28

18.8/25.5

16.9/23

73./7.4

300

253-186

0.013

3000

-

18.8/25.5

16.9/23

67/6.8

300

258-190

0.013

3000

-

18.8/25.5

16.9/23

68/6.9

300

258-190

0.013

* 2200 rpm x 9LD 625-2; 2000rpm x 9LD625/626 -2 NR/CE and 1700rpm x 9LD 625-2 EPA

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Technical information

2

9 LD engine type

Fuel type

Fuel supply

Fuel filter, internal

Filtering surface

Filter capacity

Fuel filter, external

Filtering cartridge

Filtering surface

Filter capacity

Maximum operating pressure

FUEL SUPPLY CIRCUIT

cm

2

µm

LUBRICATION CIRCUIT

cm

2

µm bar

625-2

460

7

PF 904

5000

2÷3

4

Type of lubrication

Circuit supply

Maximum oil quantity

Maximum oil quantity

Oil pressure at min. speed (oil temperature: 120°C)

Oil pressure switch

Operating pressure (min. value)

Oil filter cartridge, external

Maximum operating pressure

Maximum combustion pressure

Filter capacity

By-pass valve setting

Filtering surface

including filter (l) excluding filter (l)

Completely forced

Gear pump

3.1

2.8

bar

0.6

bar

Unipolar system

0.3

ELECTRICAL SYSTEM

bar bar

µm bar cm

2

13

20

15

1.5÷1.7

745

625/626-2

NR CE

Automotive diesel fuel (minimum cetane: 51)

Mechanical fuel lift pump (diaphragm or pistons)

460

7

PF 904

5000

2÷3

4

3.1

2.8

0.6

0.3

13

20

15

1.5÷1.7

745

625-2

EPA

460

7

PF 904

5000

2÷3

4

3.1

2.8

0.6

0.3

13

20

15

1.5÷1.7

745

Alternator, Internal Standard (nominal voltage)

Alternator, Internal Optional (nominal voltage)

Alternator, External Optional (nominal voltage)

Alternator, Internal Standard (nominal current) *

Alternator, Internal Optional (nominal current) *

Alternator, External Optional (nominal current) *

Starter motor power (Bosh GF)

Starter motor power ( Bosh DW (R) )

A

A

A kW

V

V

V kW

12

24

12

14

6

33

1.7

1.6

12

24

12

14

6

33

1.7

1.6

12

24

12

14

6

33

1.7

1.6

* (see “Alternator battery charger curve” page 66 ÷ 69)

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Technical information

PERFORMANCE DIAGRAM

9 LD 625-2 EPA @ 3000 r.p.m.

9 LD 625 NR @ 2800 r.p.m.

9 LD 625 @ 3000 r.p.m.

9 LD 626-2 @ 3000 r.p.m.

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9 LD 626-2 B2 NR @ 2800 r.p.m.

Technical information

2

9 LD 626 NR @ 3000 r.p.m.

N (80/1269/CEE - ISO 1585):

Automotive rating, intermittent operation with variable speed and variable load.

NB (ISO 3046/1 - IFN):

Rating with no overload capability, continuous light duty operation with constant speed and variable load.

NA (ISO 3046/1 - ICXN):

Continuous rating with overload capability, continuous heavy duty with constant speed and constant load.

C (NB) :

Specific fuel consumption at NB power

Mn :

Torque at N.

The above power values refer to an engine fitted with air cleaner and standard muffler, after testing and at the environmental conditions of 20°C and 1 bar. Max. power tolerance is 5%. Power decreases by approximately 1% every 100 m di altitude and by 2% every 5°C above 25°C.

Note:

Consult LOMBARDINI for power, torque curves and specific consumptions at rates differing from those given above.

Important

Non-approval by Lombardini for any modifications releases the company from any damages incurred by the engine.

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Technical information

OVERALL DIMENSION

9 LD 561-2

9 LD561-2/L

9 LD 625-2

9 LD 626-2

9 LD 626-2 NR

A

B

434

397

DIMENSIONI mm - MESURES mm - DIMENSION mm - EINBAUMAßE mm - DIMENSIONE mm - DIMEN0ÇÕES (mm)

C

D

557

217

E

F

340

168

G

H

198

425

I

L

421

178

M

N

599

633

O

P

207

542

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Technical information

2

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MAINTENANCE - RECOMMENDED OIL TYPE - REFILLING

ROUTINE ENGINE MAINTENANCE

Important

Failure to carry out the operations described in the table may lead to technical damage to the machine and/or system

AFTER THE FIRST

50 WORKING HOURS

EXTRAORDINARY MAINTENANCE

Engine oil replacement.

Oil filter replacement.

ORDINARY MAINTENANCE

OPERATION DESCRIPTION

10

ENGINE OIL LEVEL

OIL BATH AIR CLEANER

DRY AIR CLEANER

FUEL PIPES

EXTERNAL ALTERNATOR BELT TENSION

(***)

(***)

(**)

CHECK

COOLING SYSTEM CLEANING

VALVE-ROCKER ARMS CLEARANCE ADJUSTMENT

SETTING AND INJECTORS CLEANING

RUBBER INTAKE HOSE (DRY AIR CLEANER - INTAKE

MANIFOLD)

FUEL TANK CLEANING

ALTERNATOR AND STARTING MOTOR

ENGINE OIL

EXTERNAL OIL FILTER

FUEL FILTER

REPLACEMENT

EXTERNAL ALTERNATOR BELT

RUBBER INTAKE HOSE (DRY AIR CLEANER - INTAKE

MANIFOLD)

OVERHAUL

FUEL PIPES

DRY AIR CLEANER EXTERNAL CARTRIDGE

DRY AIR INTERNAL EXTERNAL CARTRIDGE

PARTIAL

TOTAL

(***)

(**)

(**)

(***)

(***)

(*)

(*)

(*)

125

FREQUENCY x HOURS

250 500 1000 2500 5000

AFTER 6 CHECKS WITH CLEANING

AFTER 3 CHECKS WITH CLEANING

(*)

(**)

(***)

- In case of low use: every year.

- In case of low use: every 2 years.

- The period of time that must elapse before cleaning or replacing the filter element depends on the environment in which the engine operates.

The air filter must be cleaned and replaced more frequently In very dusty conditions.

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Maintenance - Recommended oil type - Refilling

LUBRICANT

SAE Classification

In the SAE classification, oils differ on the basis of their viscosity, and no other qualitative characteristic is taken into account.

The first number refers to the viscosity when the engine is cold (symbol W = winter), while the second considers viscosity with the engine at régime.

The criteria for choosing must consider, during winter, the lowest outside temperature to which the engine will be subject and the highest functioning temperature during summer.

Single-degree oils are normally used when the running temperature varies scarcely.

Multi-degree oil is less sensitive to temperature changes.

-

40

-

35

-

30

-

25

-

20

-

15

-

10

-

5 0

+

5

+

10

SAE 10W-30**

+

15

+

20

SAE 10W-40**

SAE 10W-60**

SAE 15W-40 **

SAE 15W-40 **

+

25

SAE 20W-60 **

SAE 5W-30 ***

SAE 5W-40 ***

SAE 0W-30 ***

+

30

+

35

+

40

+

45

+

50

SAE- Grade

* Mineral base

** Semi-synthetic base

*** Synthetic base

3

International specifications

They define testing performances and procedures that the lubricants need to successfully respond to in several engine testing and laboratory analysis so as to be considered qualified and in conformity to the regulations set for each lubrication kind.

A.P.I

MIL

: ( American Petroleum Institute )

: Engine oil U.S. military specifications released for logistic reasons

ACEA : European Automobile Manufacturers Association

Tables shown on this page are of useful reference when buying a kind of oil.

Codes are usually printed-out on the oil container and the understanding of their meaning is useful for comparing different brands and choosing the kind with the right characteristics.

Usually a specification showing a following letter or number is preferable to one with a preceding letter or number.

An SF oil, for instance, is more performing than a SE oil but less performing than a SG one.

ACEA REGULATIONS - SEQUENCES

LIGHT DUTY DIESEL ENGINES

B1 =

Low-viscosity, for frictions reduction

B2 =

B3 =

B4 =

Standard

High performances (indirect injection)

High quality (direct injection)

HEAVY DUTY DIESEL ENGINES

E2 =

E3 =

E4 =

E5 =

Standard

Heavy conditions (Euro 1 - Euro 2 engines )

Heavy conditions (Euro 1 - Euro 2 - Euro 3 engines )

High performances in heavy conditions (Euro 1 - Euro

2 - Euro 3 engines )

API / MIL SEQUENCES

API CH-4 CG-4 CF-4 CF-2 CF CE CD CC

MIL

L- 46152 D / E

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Maintenance - Recommended oil type - Refilling

PRESCRIBED LUBRICANT

AGIP SUPERDIESEL

MULTIGRADE

10W40

specifications

API CF4 / SG

ACEA B2 - E2

MIL - L-4165 D/E

In the countries where AGIP products are not available, use oil API SJ/CF for Diesel engines or oil corresponding to the military specification MIL-L-4165 D/E.

For a temperature of -10°C an oil with a

5W40

viscosity is recommended.

For a temperature of -15°C an oil with a

0W30

viscosity is recommended.

9 LD ENGINES OIL CAPACITY

OIL VOLUME AT MAX LEVEL (OIL FILTER INCLUDED)

OIL VOLUME AT MAX LEVEL (WITHOUT OIL FILTER)

Litres

Litres

3.1

2.8

Danger - Attention

- The engine may be damaged if operated with insufficient lube oil.

- It is also dangerous to supply too much lube oil to the engine because a sudden increase in engine rpm could be caused by its combustion.

- Use proper lube oil preserve your engine.

Good quality or poor quality of the lubricating oil has an affect on engine performance and life.

- If inferior oil is used, or if your engine oil is not changed regularly, the risk of piston seizure, piston ring sticking, and accelerated wear of the cylinder liner, bearing and other moving components increases significantly.

- Always use oil with the right viscosity for the ambient temperature in which your engine is being operated.

Danger - Attention

- The used engine oil can cause skin-cancer if kept frequently in contact for prolonged periods.

- If contact with oil cannot be avoided, wash carefully your hands with water and soap as soon as possible.

- Do not disperse the oil in the ambient, as it has a high pollution power.

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Maintenance - Recommended oil type - Refilling

3

FUEL RECOMMENDATIONS

Purchase diesel fuel in small quantities and store in clean, approved containers. Clean fuel prevents the diesel fuel injectors and pumps from clogging. Do not overfill the fuel tank.

Leave room for the fuel to expand. Immediately clean up any spillage during refueling.

Never store diesel fuel in galvanized containers; diesel fuel and the galvanized coating react chemically to each other, producing flaking that quickly clogs filters or causes fuel pump or injector failure.

High sulfur content in fuel may cause engine wear. In those countries where diesel has a high sufur content, its is advisable to lubricate the engine with a high alkaline oil or alternatively to replace the lubricating oil recommended by the manufacturer more frequently. The regions in which diesel normally has a low sulfur content are Europe, North America, and Australia.

PRESCRIBED LUBRICANT

Fuel with low sulphur content

Fuel with high sulphur content

API CF4 - CG4

API CF

FUEL TYPE

For best results, use only clean, fresh, commercial-grade diesel fuel. Diesel fuels that satisfy the following specifications are suitable for use in this engine: ASTM D-975 - 1D or 2D, EN590, or equivalent.

FUELS FOR LOW TEMPERATURES

It is possible to run the engine at temperatures below 0°C using special winter fuels. These fuels reduce the formation of paraffin in diesel at low temperatures. If paraffin forms in the diesel, the fuel filter becomes blocked interrupting the flow of fuel.

Fuel can be: - Summer up to

- Winter

- Alpine

- Arctic up to up to up to

0°C

-10°C

-20°C

-30°C

BIODIESEL FUEL

Fuels containing less than 20% methyl ester or B20, are suitable for use in this engine. Biodiesel fuels meeting the specification of BQ-9000, EN 14214 or equivalent are recommended. DO NOT use vegetable oil as a biofuel for this engine.

Any failures resulting from the use of fuels other than recommended will not be warranted.

EMISSION CONTROL INFORMATION

LOW SULFUR FUEL OR

ULTRA LOW SULFUR FUEL ONLY

AVIATION FUEL

Aviation fuels suitable for use in this engine include JP5, JP4, JP8 and, JET-A (if

5 percent oil is added).

EPA /CARB emission label must be attached near the fuel inlet.

Capacities standard fuel tank

Litres

As for filters, tanks and special crankcases please refer to LOMBARDINI instructions.

10

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DISASSEMBLY / REASSEMBLY

RECOMMENDATIONS FOR DISASSEMBLING AND ASSEMBLING

Important

To locate specific topics, the reader should refer to the index.

Besides disassembly and reassembly operations this chapter also includes checking and setting specifications, dimensions, repair and operating instructions.

Always use original LOMBARDINI spare parts for proper repair operations.

The operator must wash, clean and dry components and assemblies before installing them.

The operator must make sure that the contact surfaces are intact, lubricate the coupling parts and protect those that are prone to oxidation.

Before any intervention, the operator should lay out all equipment and tools in such a way as to enable him to carry out operations correctly and safely.

For safety and convenience, you are advised to place the

engine on a special rotating stand for engine overhauls.

Before proceeding with operations, make sure that appropriate safety conditions are in place, in order to safeguard the operator and any persons involved.

In order to fix assemblies and/or components securely, the operator must tighten the fastening parts in a criss-cross or alternating pattern.

Assemblies and/or components with a specific tightening torque must initially be fastened at a level lower than the assigned value, and then subsequently tightened to the final torque.

RECOMMENDATIONS FOR OVERHAULS AND TUNING

Important

To locate specific topics, the reader should refer to the index.

Before any intervention, the operator should lay out all equipment and tools in such a way as to enable him to carry out operations correctly and safely.

The operator must comply with the specific measures described in order to avoid errors that might cause damage to the engine.

Before carrying out any operation, clean the assemblies and/or components thoroughly and eliminate any deposits or residual material.

Wash the components with special detergent and do not use steam or hot water.

Do not use flammable products (petrol, diesel, etc.) to degrease or wash components. Use special products.

Dry all washed surfaces and components thoroughly with a jet of air or special cloths before reassembling them.

Apply a layer of lubricant over all surfaces to protect them against oxidation.

Check all components for intactness, wear and tear, seizure, cracks and/or faults to be sure that the engine is in good working condition.

Some mechanical parts must be replaced

en bloc

, together with their coupled parts (e.g. valve guide/valve etc.) as specified in the spare parts catalogue.

1

- 26 -

AIR CLEANER

Oil-bath air cleaner

Check gaskets and replace if necessary.

Check that flange weld is free of porosity or defective spots.

Carefully clean bowl and filtering element with Diesel oil and blow through with compressed air.

Top up with engine oil to the mark.

When refitting tighten nuts at 25 Nm.

See page 22 for periodic maintenance details.

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Components:

1

Bowl

2

Oil level mark

3

Filtering element

4

Seal ring

5

Internal seal ring

6

Cover

7

Clamp

8

Prefilter

Disassembly / Reassembly

4

2

Dry air cleaner

Components:

1

Hand wheel

2

Cover

3

Cartridge

4

Seal ring

5

Bracket

6

Clogging indicator

Important

Replace cartridge immediately when indicator shows that is clogged.

3

4

Dry air cleaner, Donaldson type

Danger - Attention

Never clean the filter element using highly flammable solvents.

It could cause an explosion!

In order to know how often you should check and replace the air filter cartridge and the rubber hose (air filter – intake manifold) see page 22.

1

Main cartridge

2

Safety cartridge

3

Axial cover

4

Scavenging valve

5

Cap complete with clamp

Scavenging valve

4

must be positioned as in figure 4.

Danger - Attention

During repair operations, when using compressed air, wear eye protection

.

The cartridge can be cleaned by blowing compressed air breadthways outside and inside the cartridge, at a pressure not greater than 5 atmospheres, or in necessity case by knocking the front of the cartridge several times against a flat surface.

Use a lamp to check that the filter element is not damaged or inspect it against the light while slanted.

In case of doubt, install a new cartridge.

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Disassembly / Reassembly

Clogging indicator

Components

:

1

Reset button

2

Transparent indicator

Note:

Indicator is calibrated at 600÷650 mm column of water.

5

Oil vapour separator

Fitted on engines with dry air cleaner.

Screw it out of the air conveyor support, carefully wash with gasoline inside and blow out with compressed air.

When refitting replace the copper gasket and connect the oil vapour separator with intake manifold by means of the special rubber hose.

6 7

8

MANIFOLDS, INTAKE/EXHAUST

Intake manifold

To avoid flange breakage check that heads are in line before tightening nuts.

Check flange surface for warpage and correct if necessary.

Replace gaskets.

Tighten nuts at 25 Nm.

Note:

In case of low temperature starting we can supply a manifold with possibility of fitting a glow plug with air preheating.

Exhaust manifold

Check that the inside is clean.

To avoid flange breakage check that heads are in line before tightening nuts.

Replace gaskets.

Tighten nuts at 20 Nm.

9

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Disassembly / Reassembly

EXTERNAL ALTERNATOR CONTROL BELT

(only for engines with external alternator)

External alternator blower control belt - Disassembly

Release the two alternator fastening bolts.

Unscrew the fastening nuts of the belt guard and remove it.

Remove the

V

belt.

See page 22 for periodic maintenance details.

4

10

External alternator blower control belt – Tension check

Important

Carry out checks only after isolating the positive battery cable to prevent accidental short-circuiting and, consequently, the activation of the starter motor.

Tension the belt if it flexes more than 1 cm exerting a pressure of

10 kg.

11

External alternator blower control belt - Reassembly

Install the belt and the belt guard.

Force the alternator outwards and temporarily tighten the fastening bolts.

Make sure that the belt tension is within the required parameters (see

“External alternator blower control belt – Tension check”, Fig. 11).

Tighten the fastening bolts to a final torque of 30 Nm (8x1.25) and

50 Nm (10x1.50).

12

FUEL TANK

After disconnecting the fuel pipes unscrew the anchoring brackets' screws and remove the fuel tank.

Completely empty the tank and check that no impurities are found inside.

If the fuel tank is fitted wth an internal fuel filter remove and replace the cartridge.

Check that cap breather hole is not clogged.

Remove the tank support.

When refitting tighten the support screws at 40 Nm and the bracket screws at 8 Nm.

See page 57 for refitting internal fuel filter.

13

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Disassembly / Reassembly

14

Pulley guard - Shroud - Side plates

Components

:

1

Pulley guard

2

Shroud

3

Side plates

The pulley guard is made of sound deadening material: it reduces the noise that both the pulley and the fan tend to amplify.

Shroud and side plates are made of ANTIFON, an elastic Iayer which absorbs the noise caused by the plate vibrations.

Cooling fan

Carefully clean and check all blades and inserts. Replace the fan even if there is only a single damaged blade or only a single released insert.

See page 16 for cooling air flow.

Tighten the fan's fixing screws at a torque of 10 Nm.

15

16

Hub

Components

:

1

Hub

2

Alternator rotor

3

Fan

4

Bolt

The hub holds the alternator rotor and the cooling fan.

Unscrew the bolt clockwise and tighten at 160 Nm when refitting.

Internal alternator

Remove stator and place it inside the rotor to prevent metal particles from being attracted by the magnets.

When refitting tighten rotor screws and stator bolts at 10 Nm.

See page 67 ÷ 69 for alternator characteristics.

17

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Disassembly / Reassembly

4

Shroud support (Gear cover plate)

Loosen screws and remove shroud support very carefully to avoid damage to the oil seal ring.

When refitting check that gaskets

A

and oil seal ring

B

are well inside their housings.

Tighten screws at 25 Nm.

18

19

FLYWHEEL

Remove flywheel with puller

1

(part N°. 7271-1460-119).

Check starter ring gear and tapered crankshaft mating surfaces.

When refitting tighten bolt al 300 Nm.

In order to replace the ring gear, it is necessary to disassemble the flywheel.

Cut the ring gear in several places using a chisel and remove it.

Important

Remove any debris and carefully clean the ring gear.

Heat the new ring gear uniformly and keep it at a temperature of 300°C for15÷20 minuti.

Danger – Attention

Risk of burning: be careful of hot surfaces.

Insert the ring gear into its seat and place it carefully on the rim of the flywheel.

Leave to the ring gear to cool gently before reassembling the flywheel.

20

ROCKER ARMS

Valve / Rocker arm clearance

Important

Setting should be performed when the engine is cold.

Remove rocker arm cover and check gaskets for breakage.

Bring each cylinder piston to top dead center on the compression stroke and set clearance

A

al 0.15÷0.20 mm for intake and 0.30÷0.35 mm for exhaust.

When refitting tighten cover screws by 20 Nm.

21 22

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23

24 25

Compression release (optional)

Bring piston to top dead center on the compression stroke.

Unscrew rocker arm cover side plug and measure clearance

A

between lever and rocker arm, which must be 0.30÷0.40 mm.

For setting purposes remove the rocker arm cover, unscrew the lock nut

C

and set clearance

A

by changing the height of the shims under the plate

B

.

Set the valve/rocker arm clearance, see "Valve / Rocker arm clearance" on page 31.

Reassemble the rocker arm cover and check the decompression lever clearance again.

Rocker arm assembly

Components

:

1

Bore

2

Lubrication tube

Dimensions

(mm):

A

= 18.032÷18.050

B

= 17.989÷18.000

If clearance (

A

-

B

) exceeds 0.135 mm replace shaft and rocker arms.

Caution – Warning

When retitting check that lubrication tube perfectly matches with the journal bore.

On slow engines, which are set to 1,500 – 1,800 rpm, the rocker arms differ from the standard version in the upper part of the lubrication channel.

Tighten the rocker arm shaft fastening screws to the head at a torque of 25 Nm.

26

- 32 -

INJECTOR

Clean injector and check calibrated pressure as indicated on page 65.

When refitting check that it correctly protrudes from the cylinder head plane.

Tighten the fixing nuts at 10 Nm.

Tighten the high-pressure pipe union at 25 Nm.

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28

29

Disassembly / Reassembly

4

Injector for EPA and 97/68 CE engines

The injector is attached to the cylinder head via a forked bracket.

Tighten the fixing bracket screw at 10 Nm.

Fix the high-pressure hose union to the injector union at 25 Nm.

Injector projection

The end of nozzle

A

should project 3.0÷3.5 mm. from the cylinder head plane.

Adjust injector projection by means of copper shims

B

measuring 0.5,

1.00 and 1.50 mm in thickness.

CYLINDER HEAD

Important

Do not remove it when hot to avoid deformation.

The cylinder heads must be tightened with the exhaust or intake manifold mounted to keep them lined up.

lf cylinder head is deformed level it off by removing a maximum of 0.3 mm.

When refitting tighten only if sure that rocker arm lubrication tube is well inside its holes, and that the rubber seals of the tappet hose are assembled and inserted correctly into their seats.

Always replace copper head gasket: see page 39 for choosing the right thickness.

Progressively tighten nuts in the

1

,

2

,

3

,

4

sequence at 55 Nm.

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30 31

Valves

Components:

1

Intake valve

2

Spring seat

3

Valve stem seal ring

4

Spring

5

Retainer

6

Half collets

To remove half collets firmly press down as shown in the figure.

Valve stem sealing rings - Reassembly

Lubricate the inside of the sealing ring with Molikote BR2 Plus and insert them all the way onto the guides using tool 1460-108.

To prevent deformation of the sealing ring

1

as it is inserted onto the valve guide

2

insert it onto tool

3

.

Lubricate valve stem with the same type of grease; insert the valves into the guides rotating them particularly as they enter the sealing ring.

32 33

34

35

- 34 -

36

Valve springs

Measure free length with a gauge.

Using a dynamometer check that the spring length under two dìfferent loads corresponds to the values below:

Free length

A

= 52 mm

Length

B

compressed by a 210.6 N = 35.8 mm

Length

C

compressed by a 340.6 N = 25.8 mm

Replace spring if length is 1 mm or more below the stated values.

Valve material

Intake valves A

Material: X 45 Cr Si 9-3 UNI En 10090

1

Chromium-plated portion

a

45.5° ÷ 45.75°

Exhaust valve B

Shaft and head are made of 2 different materials.

2

Welded portion

3

Chromium-plated portion

4

Portion made of X 45 Cr Si 9 - 3 UNI EN 10090

5

Portion made of X 55 Cr Mn Ni N 20 - 8 UNI EN 10090

a

45.5° ÷ 45.75°

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Valve guides and valve guide housings

Starting from engine No. 2883619 intake and exhaust valve guides are both made of phosphoric cast iron.

Components:

1

= Exhaust valve guide

2

= Intake valve guide

Ref

A

B

C

D

.

Dimensions

(mm)

4 2 .

0

4 8

1 4 .

0 0 0 ÷ 1 4 .

0 1 8

1 4 .

0 4 5 ÷ 1 4 .

0 5 6

Valve guides with outside diameter increased by 0.5 mm. are also available;in such cases valve guide bore

C

shouid also be increased by 0.5 mm.

Valve guide insertion

Heat cylinder head up to 160÷180°C

Press guides considering the

A

and

B

distances from the head plane.

Ref

.

A

B

Dimensions

3 0 , 8 0 ÷

2 4 , 8 0 ÷

(mm)

3 1 , 2 0

2 5 , 2 0

38

Dimensions and clearance between guides and valves

Ref

.

A

B

Dimensions

(mm)

8 , 0 2 5 ÷ 8 , 0 4 0 *

7 , 9 8 5 ÷ 8 , 0 0 0

Clearance

(mm)

0 , 0 2 5 ÷ 0 , 0 5 5

Limit value

(mm)

0 , 1 5

* with driven guide.

39

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40

ExHAuST vALvE

INTAKE vALvE

Valve seats and housings

Ref

A

B

C

D

.

Dimensions

(mm)

4 0 .

0 0 0 ÷ 4 0 .

0 1 6

4 0 .

0 8 1 ÷ 4 0 .

0 9 5

3 4 .

0 0 0 ÷ 3 4 .

0 1 6

3 4 .

0 8 1 ÷ 3 4 .

0 9 5

Press valve seats into the housings and cut at 45°.

Valve seat grinding

After cutting grind valve seats with fine emery paste in oil suspension.

The sealing surface

S

should not exceed 2 mm.

Valve recess after grinding

D

= 0.75÷1.25 mm; maximum worn limit

1.65 mm.

41 42

Pushrod tube

When refitting cheek that gaskets

A

and rocker arm lubricatíon tube

C

are well inside their seats.

44

- 36 -

43

125° ÷ 135°

CYLINDER

Checks and cylinder roughness

Fins must be intact.

Cross hatch pattern must range between 125°÷135°: they must be uniform and clear in both directions.

Average roughness should range between 0.35 and 0.60 µm.

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Measure diameter size between two diametrically opposed points at three different heights.

As per the cylinder sizes, see Table “Piston and cylinder types and sizes".

45 46

PISTON

Remove circlips and remove piston pin.

Remove piston rings and clean grooves.

Measure diameter at 17 mm from the bottom of skirt.

47 48

Table “Piston and cylinder types and sizes"

Class

A

B

C

Ø Piston (mm)

9 4 .

9 2 ÷ 9 4 .

9 3 *

9

4 .

9 3 ÷ 9 4 .

9 4 *

9 4 .

9 4 ÷ 9 4 .

9 5 *

Ø Cylinder (mm)

9 5 .

0 0 ÷ 9 5 .

0 1 *

9 5 .

0 1 ÷ 9 5 .

0 2 *

9 5 .

0 2 ÷ 9 5 .

0 3 * *

Clearance (mm)

0 .

0

* In case of diameter wear above 0.05 mm replace piston and piston rings.

** In case wear exceeds 0.10 mm, bore the cylinder and fit oversize piston and rings.

In case of less wear replace piston rings only.

Note:

Oversize pistons of 0.5 and 1 .0 mm are available (only for standard and 97/68 CE engines).

7 ÷ 0 .

0 9

Important

The cylinder heads must be tightened with the exhaust or intake manifold mounted to keep them lined up.

The cylinder and piston must be replaced with a new cylinder and piston of the same class.

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Piston weight

Weigh pistons when replacing them in order to avoid unbalance.

Important

The difference in weight should not exceed 6 g.

49

50

Piston rings - End gaps (mm)

Place piston rings squarely into the unworn part of the lower cylinder and measure the end gap.

1 ° Chromium-plated ring

A

0 .

4 0 m m ÷ 0 .

6 5 m m

2 °

3 °

Torsional internal tapered ring

Oil control ring

0 .

4 0 m m ÷ 0 .

6 5 m m

0 .

3 0 m m ÷ 0 .

6 0 m m

Pistons rings - Clearance between grooves (mm)

Ref

A

B

C

.

Dimensions

(mm)

0,07÷0,11

0,05÷0,09

0,04÷0,08

Limit value

(mm)

0,20

0,16

0,15

51 52

53

- 38 -

Piston rings - Fitting sequence

A

= 1° Chromium-plated ring

B

= 2° Torsional (internal tapered) ring

C

= 3° Oil control ring

Important

Before fitting the piston into the cylinder stagger the ring gaps at 120°.

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Piston - Refitting

Connect piston to connecting rod in a way that the combustion chamber centre

b

is at right angle under nozzle tip

a

.

Lubricate piston pin and introduce it into the piston by exerting pressure with your thumb.

Check that both circlips are well inside their seats.

54 55

Piston clearance

Piston clearance = 0.65 ÷ 0.70 mm, for standard engines

= 0.55 ÷ 0.60 mm, for 97/68 CE and EPA engines

The piston in the

TDC

(top dead centre) position may extend or be short of the upper surface of the cylinder.

Use a dial indicator to measure the difference between the two surfaces (piston crown and upper cylinder surface) and use a suitable thickness copper gasket

B

for the cylinder head to adjust the clearance volume

A

.

(See image below)

56 57

Head seal thickness

Distance between the piston at the top dead centre and the cylinder surface

CONNECTING ROD

Remove the oil sump.

Remove the connecting rod cap.

Important

Both connecting rod/piston units should be fitted back into the corresponding cylinders; mark them so as to identify the correct combination during reassembly.

See page 40 for specifications as to the tightening of the connecting rod big end bearing.

58 59

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Connecting rod small end bushing

Dimensions and clearance (mm):

C

= 25.020÷25.030 (with machined bushing in place)

D

= 24.995÷25.000

(C-D)

= 0.020÷0.035

(C-D)

maximum worn limit = 0.070

60

Connecting rod alignment

Check alignment of small end and big end bearing bores using fitted mandrels; axial mis-alignment

A

= 0.02 mm; maximum limit = 0.05 mm.

61

62

63

- 40 -

Connecting rod weight

Weigh connecting rods when replacing them in order to avoid unbalance.

Important

The difference in weight should not exceed 10 g.

Connecting rod big end bearing

Both centering notches of the bearings

A

and

B

must be on the same side when refitting.

Tighten bolts at 40 Nm.

See page 44 for dimensions.

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Disassembly / Reassembly

CRANKSHAFT TIMING GEAR

4

Disassembly:

Use tool

1

(Part N°. 7560-4000-052) and puller

2

(Part N°. 7271-1460-

119) to remove the gear.

Reassembly:

Heat the gear uniformly and keep it at a temperature of 300 °C for 15

– 20 minutes.

Caution – Warning

Danger of burning: pay attention to the hot surfaces.

Insert the gear into its seat by inserting the activation key into the gear opening and push until it comes into contact with the driving shaft.

Let it slowly cool down.

66

MAIN BEARING SUPPORTS

Main bearing support, gear side

Remove main bearing by means of two M8x1.25 screws with fully threaded length of 40 mm or a puller (Part N°. 7271-1460-119).

Note:

To avoid deformation it is not recomended to replace the bearing bushing, complete assembly's of bushing and support are available in standard, 0.25 mm and 0.50 mm undersize configurations as spare parts.

When refitting tighten the screws at 30 Nm.

See page 44 ÷ 45 for dimensions.

Main bearing support, flywheeI side

Remove it by means of two M8x1.25 screws with fully threaded length of 40 mm.

Check oil seal ring and replace if warped, hardened or worn-out.

When refitting, tighten nuts at 30 Nm.

See end float on page 45 for gasket replacement detaiis.

See page 44 ÷ 45 for dimensions.

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CRANKSHAFT

Center main bearing support, locating screw.

Straighten plate

1

and unscrew screw

2

before removing crankshaft.

When assembling tighten the screw at a torque of 30 Nm.

68

Crankshaft removal

To pull out the crankshaft tap lightfy on the timing side end using a copper-headed hammer.

When refitting align center main bearing support so that the locating screw hole coincides with the crankcase hole.

69

Crankshaft center main bearing support

When refitting, both centering notches

A

and

B

must be located on the same side.

Tighten screws at 25 Nm.

See page 44 ÷ 45 for dimensions.

70

71

- 42 -

72

Crankshaft lubrication ducts

Danger - Attention

During repair operations, when using compressed air, wear eye protection

.

Remove plugs, clean duct

A

with a pointed tool and blow in compressed air. Screw plugs again and check for sealing.

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Disassembly / Reassembly

Crankshaft journal radius

The radius

R

connecting journals to shoulders is 2.8÷3.2 mm.

4

Important

When grinding external main journals restore the R value to original specification.

Checking main journals and crank pins

Use an outside micrometer gauge.

74

75

Main journal and crank pin diameter

Ref

.

C

D

A

B

Dimensions

(mm)

5 4 .

9 3 1 ÷ 5 4 .

9 5 0

4 5 .

5 0 0 ÷ 4 5 .

5 1 6

5 5 .

3 3 1 ÷ 5 5 .

3 5 0

5 4 .

9 3 1 ÷ 5 4 .

9 5 0

How to measure main bearing inside diameter

Use an inside micrometer gauge.

76

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77

78

79

80

- 44 -

Main bearing and connecting rod big end bearing inside diameter

Ref

.

Dimensions

(mm)

E

F

5 5 .

0 0 0 ÷ 5 5 .

0 2 0

4 5 .

5 4 8 ÷ 4 5 .

5 7 8

G 5 5 .

4 0 4 ÷ 5 5 .

4 3 5

H 5 5 .

0 0 0 ÷ 5 5 .

0 2 0

The above dimensions refer to driven in or tightened bearings.

Note:

Both main bearings and connecting rod big end bearings are available with inside diameter size measuring 0.25 and 0.50 mm less than the standard version.

Clearance between main journals/crank pins and connecting rod bearings

Ref

.

E A

F B

G C

H D

Clearance

(mm)

0 .

0 5 0 ÷ 0 .

0 8 9

0 .

0 3 2 ÷ 0 .

0 7 8

0 .

0 5 4 ÷ 0 .

1 0 4

0

.

0 5 0 ÷ 0 .

0 8 9

Limit value

0 .

0 .

0 .

1 8 0

1 5

0

0 .

1 9

1 8

0

0

(mm)

Main bearíng supports -

Dimensions

1

Flywheel side

2

Central

3

Gear side

Ref

.

I

L

M

N

Q

R

O

P

Dimensions

(mm)

1 4 9 .

0 0 0 ÷ 1 4 9 .

0 2 0

6 0 .

0 0 0 ÷ 6 0 .

0 2 0

1 4 7 .

0 0 0 ÷ 1 4 7 .

0 1 8

5 9 .

0 7 4 ÷ 5 9 .

0 9 3

7 5 .

9 9 0 ÷ 7 6 .

0 1 0

6 0 .

0 0 0 ÷ 6 0 .

0 2 0

2 3 .

9 5 ÷ 2 4 .

0 5

3 1 .

1 0 ÷ 3 1 .

2 0

Main bearing housings

Ref

.

A

B

C

Dimensions

(mm)

1 4 9 , 0 0 0 ÷ 1 4 9 , 0 2 0

1 4 7 , 0 0 0 ÷ 1 4 7 , 0 2 0

7 6 , 0 0 0 ÷ 7 6 , 0 2 0

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4

Table “Clearance between main bearings and main bearing housings”

Ref

A-I

B-M

C-O

.

Clearance

(mm)

-0,020÷0,020

-0,018÷0,020

-0,010÷0,030

Limit value

0,03

0,03

0,04

(mm)

Crankshaft end play

When refitting crankshaft check end play by means of a thickness gauge; this value should be 0.08 ÷ 0.38 mm and can be set by changing the thickness of gasket

A

which is located on the flywheel-side main bearings.

Gaskets with thickness of 0.30 and 0.50 mm can be supplied.

Important

Replace the main bearings 1 and 3 (Fig. 79) if the axial clearance value still turns out to be too high even with a seal having a smaller thickness (fig. 79).

CAMSHAFT

How to measure camshaft journals and housings

Use an inside micrometer gauge for housings and an outside micrometer gauge for journals.

82 83

Dimensions of camshaft journals and housings

Ref

.

B

D

A

C

Dimensions

(mm)

41,940÷41,960

42,000÷42,025

27,940÷27,960

28,000÷28,025

Clearance

(mm)

0,040÷0,085

0,040÷0,085

Limit value

(mm)

0,160

0,150

84

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85 86

How to measure intake/exhaust cam height

A1

= 1 st cylinder intake cam

S1

= 1 st cylinder exhaust cam

A2

= 2nd cylinder intake cam

S2

= 2nd cylinder exhaust cam

Exhaust and intake cams feature the same height

H

.

H

= 33.625 ÷ 33.650 mm

Replace camshaft if

H

is 0.1 mm below the given value.

Camshaft end play

End play should be 0.10÷0.25 mm; check by means of a dial gauge pushing or pulling camshaft as required.

87

CAMSHAFT TIMING

Fit camshaft gear by making timing mark

1

coincide with timing -mark

2

on the crankshaft timing gear.

Tighten camshaft boll at 60 Nm.

88

89

- 46 -

Valve timing without considering timing marks

Locate piston

1

(on flywheel side) at the top dead centre.

Position two small cylinders

A

of the same height onto the tappets.

Rotate camshaft stopping when cylinder

1

tappets are in overlap position

(intake open, exhaust closed).

By means of ruler

B

check that tappets are at the same height.

Engage camshaft gear with crankshaft gear.

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Disassembly / Reassembly

4

Valve timing check

Check valve timing at the crankshaft.

The values shown are checked at the flywheel circumference (with flywheel of 291 mm. diameter each degree corresponds to 2.5 mm).

Set valve clearance at 0.65÷0.70 mm (after checking restore the value at 0.15÷0.20 mm).

Set dial gauge on intake valve to a zero value; by rotating the driving shaft according to its direction of rotation you can measure α (intake valve opening advance referred to top dead centre

S

) and

ß

(intake valve closing delay referred to bottom (

I

) dead centre).

Follow the same procedure for exhaust valves checking γ (exhaust valve opening advance) and δ (exhaust valve closing delay).

Valve timing - Angles

The angle values are determined by turning the driving shaft clockwise

S

= Piston at top dead centre

I

= Piston at bottom dead centre

α

= Intake valve open

β

= Intake valve closed

γ

= Exhaust valve open

δ

= Exhaust valve closed

Timing angles for checking puposes

(valve clearance = 0,65÷0,70 mm)

α

= 1° before

S

β

= 21° after

I

γ

= 23° before

I

δ

= 1° after

S

91

HYDRAULIC PUMP

Hydraulic pump p.t.o

A hydraulic pump of group 1 (

1P

) or 2 (

2P

) can be installed on the gear side, 3rd p.t.o.

92

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93

Hydraulic pump components (1 P)

1

Seal ring

2

Centering ring

3

Coupling

4

Half coupling

5

Flange

6

Gear

7

Bracket

8

Thrust washer

9

Stop ring

10

Cover

The maximum total torque is thus 30 Nm corresponding to 12.5 HP at

3000 r.p.m. Reduction ratio 1:1.

MECHANICAL SPEED GOVERNOR

Weight-type governor housed inside the camshaft drive gear.

94

95

Mechanical speed governor components

1

Gear

2

Weight

3

Mobile bell

4

Stop ring

5

Thrust washer

6

Yoke

7

Lever

8

Drive rod

9

Governor spring

10

Rack control lever

Weights are moved to the periphery by the centrifugal force and thus axially shift a mobile bell connected to the injection pump rack control lever by a linkage.

A spring placed under tension by the accelerator control offset the weight centrifugal force.

Balance between the two forces keeps speed at an almost constant level in spite of load variations.

See page 62 for timing.

- 48 -

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7

Disassembly / Reassembly

4

Governor springs with rocker arm system

The system features two springs anchored to a rocker arm and allows for minimal r.p.m. changes at low speed levels.

The device is operated automatically: when the engine is stopped spring

6

acts on injection pump control yoke

7

providing maximum fuel delivery, until the engine starts and the governor controls the iniection pump rack.

96

97

6

2

4

5

3

1

4

Components:

1

Rocker arm for spring anchoring

2

Governor springs

3

Plate

4

Link

5

Throttle lever

6

Supplementary start-up fuel spring

1

2

Governor springs with single-spring system

1

Extra fuel spring

2

lnjection pump control lever

3

Governor spring

4

Throttle lever

3

98

5

3

4

6

1

7

2

ELECTRONIC SPEED GOVERNOR

(optional)

1

lnjection pump control lever

2

Electromagnet

3

Eccentric screw

4

Conical plug

5

Conical plug

6

Actuator

7

Eccentric screw

Assemble the entire plate by centring it on the reference pins and make sure that the injection pump rack rod pin is inside lever “

1

”. Fix the plate by using the specific screws for its model.

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Disassembly / Reassembly

5

3

2

6

1

4

7

Adjustment of the stroke end (STOP):

1 - Remove the conical plug "

5

".

2 - Through the eccentric "

7

" position and check by sight that the lever in stop position is at the extreme left.

3 - From this position, always acting on the eccentric screw "

7

", move the control lever 1,0 ÷ 1,5 mm to right.

4 - Lock the lock nut of the screw "

7

".

5 - Reassamble the conical plug "

5

".

Adjustment of extra fuel delivery:

1 - Remove the conical plug "

4

".

2 - Power the electromagnet "

2

" with a 12V voltage and make sure that the plunger has moved. In this case you will hear the typical activated magnet sound.

3 - Feed actuator "

6

" with a tension of 12V (put between the actuator and the 12V a 10 Amp. fuse): the actuator tension will cause the pump delivery control lever to move to the right.

4 - By the eccentric screw "

3

" place and check by sight that the lever in Max position is at the extreme right; from this position, always acting on the screw "

3

", move the delivery control lever by 1,0 ÷

1,5 mm to the left .

5 - Lock the lock nut of screw "

3

".

6 - Remove feeding from actuator "

6

" e electromagnet "

2

".

7 - Reassamble the conical plug "

4

".

100

Magnetic sensor

Speed governor wiring diagram

Black

Red shielding

101

- 50 -

24V electric control unit

shielding

White

Black

Violet

Red

Black

Violet

Starting motor

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9LD Workshop Manual _ cod. ED0053022860 -

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03 - 51 -

5

LUBRICATION SYSTEM

LUBRICATION SYSTEM AND BREATHER RECIRCULATION SYSTEM

Danger – Attention

- The engine can be damaged if allowed to operate with insufficient oil. It is also dangerous to add too much oil because its combustion may lead to a sharp increase in the rotation speed.

- Use suitable oil in order to protect the engine.

Nothing more than lubrication oil can influence the performances and life of an engine.

- Use of an inferior quality oil or failure to regularly change the oil will increase the risk of piston seizure, will cause the piston rings to jam and will lead to rapid wear on the cylinder liner, the bearings and all other moving parts.

Engine life will also be notably reduced.

- The oil viscosity must suit the ambient temperature in which the engine operates.

Danger – Attention

- Old engine oil can cause skin cancer if repeatedly left in contact with the skin and for long periods of time.

Wear protective gloves to avoid touching used oil.

- If contact with the oil is unavoidable, you are advised to wash your hands with soap and water as soon as possible.

Dispose of old oil in the correct way as it is highly polluting

.

Standard lubrication system circuit

1

2

3

4

5

6

7

13

14

11

12

15

9

10

8

102

Components:

1)

Oil preassure gauge

2)

Breather

3)

Connecting rod big end bearing

4)

Crankshaft main bearing on gear side

5)

Cartridge filter

6)

Oíl pressure relief valve

7)

Oil pump

8)

Internal filter

- 52 -

9)

Oil fill plug

10)

Rocker arm shafts

11)

Pushrod protection tube

12)

Hydraulic pump gear

13)

Camshaft joumal on fiywheel side

14)

Oìl dipstick

15)

Oil drain plug

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03

1

2

3

4

5

6

7

8

103

Components:

1)

Oil pressure gauge

2)

Breather

3)

Connecting rod big end bearing

4)

Crankshaft main bearing on gear side

5)

Cartridge filter

6)

Oíl pressure relief valve

7)

Oil pump

8)

Internal filter

Lubrication system with oil radiator circuit

16

Lubrication system

5

9

10

13

14

11

12

15

9)

Oil fill plug

10)

Rocker arm shafts

11)

Pushrod protection tube

12)

Hydraulic pump gear

13)

Camshaft joumal on fiywheel side

14)

Oìl dipstick

15)

Oil drain plug

16)

Oil radiator

OIL PUMP

Check that the gear teeth are intact and that clearance between gear edge and pump body does not exceed 0.15 mm.

Furthermore check that the control shaft is free to rotate with end float not exceeding 0.15 mm.

Oil pump delivery at 3000 r.p.m. is 9 liters/min.

104 105

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5

Lubrication System

106

6 1

107

3

2

4

5

OIL FILTER CARTRIDGE (EXTERNAL)

Components

:

1

Gasket

2

Plate

3

Gommino

4

Spring

5

Filter element

6

Bypass valve

7

Spring

For characteristics see page 17.

OIL PRESSURE RELIEF VALVE

Details

:

1

Plunger

2

Washer

3

Valve body

4

Spring

5

Ring snap

6

M9x1 threading for puller

Operation start pressure .............................5 bar.

Disassembly

:

Before removing the oil pressure regulating valve, remove the oil filter by using an appropriate wrench.

Remove the regulating valve using a hammer puller equipped with a

M9x1 threaded terminal.

108

Reassembly:

Make sure that the valve seat is free of scratches and scores which could reduce the pressure seal.

Insert the entire oil pressure valve into its housing by keeping it in line.

Make sure that the valve is completely assembled to the engine guard by means of a pad.

109

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03

Lubrication system

5

OIL PRESSURE CHECK

Once the engine is fitted fill with oil and fuel; connect a 10 bar pressure gauge to the fitting.

Start the engine and check pressure as a function of the oil temperature .

110

Oil pressure curve with engine at idle speed

The curve is obtained at the oil filter lever with constant engine speed of

1200 r.p.m. in no-load conditions and at a room temperature of + 25°C.

Pressure is given in bar and temperature in centigrades.

If the oil pressure value is below the indicated one, please check all components indicated on page 52 ÷ 53.

111

Oil pressure curve with engine at full speed

The curve is obtained at the oil filter level with engine working at 3000 r.p.m. and max. power at + 25°C room temperature.

Pressure is given in bar and temperature in centigrades.

If the oil pressure value is below the indicated one, please check all components indicated on page 52 ÷ 53.

112

3

2

4

4

4

5

1

OIL RADIATOR

(on request)

Components

:

1

Radiator

2

Return pipe

3

Oil filter

4

Copper gasket

5

Delivery hose

6

Union

7

Oil detection flange

8

O-ring

6

7

8

113

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6

FUEL SYSTEM

114

8

7

6

5

115

8

7

9

116

6

9

8

7

117

- 56 -

6

FUEL FEEDING / INJECTION CIRCUIT

Fuel feeding / injection circuit with fuel filter inside the fuel tank

Components

:

1

Fuel tank

2

Fuel filter

3

Fuel feeding tube

4

Fuel lift pump

5

lnjection pump

6

High-pressure pipe

7

Injector

8

Injector exhaust pipe

2

1

3

Fuel feeding / injection circuit with external fuel filter

Components

:

1

Fuel tank

2

Fuel feeding tube

3

Fuel filter

4

Fuel lift pump

5

lnjection pump

6

High-pressure pipe

7

Injector

8

Injector exhaust pipe

4

5

10

10

5

4

4

1

2

3

Fuel feeding / injection circuit with external fuel filter and double solenoid valve

Components

:

1

Fuel tank

2

Solenoid valve

3

Fuel filter

4

Fuel lift pump

5

Solenoid valve

6

lnjection pump

7

High-pressure pipe

8

Injector

9

Injector exhaust pipe

10

Non-return valve

2

1

3

Fuel feeding / injection circuit with fuel filter inside the fuel tank and double solenoid valve

Components

:

1

Fuel tank

2

Fuel filter

3

Solenoid valve

4

Fuel lift pump

5

Solenoid valve

6

lnjection pump

7

High-pressure pipe

8

Injector

9

Injector exhaust pipe

10

Non-return valve

9LD Workshop Manual _ cod. ED0053022860 -

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03

9

10

8

7

118

6

119

5

4

2

1

3

Fuel system

6

Fuel feeding / injection circuit with external fuel filter and QSD

(Quick Stop System)

Components

:

1

Fuel tank

2

Fuel feeding tube

3

Fuel filter

4

Fuel lift pump intake tube

5

Fuel lift pump delivery tube

6

Fuel lift pump

7

lnjection pump

8

High-pressure pipe

9

Injector

10

Injector exhaust pipe

FUEL FILTER

Fuel filter (inside fuel tank)

Components

:

1

Spring

2

Disc

3

Ring

4

Cartridge

5

Gasket

6

Gasket

7

Cap

8

Ring

9

Screw

For characteristics see page 17.

Fuel filter, external

1

Air relief valve

2

Support

3

Cartridge

4

Gasket

5

Filtering element

For characteristics see page 17.

For maintenance see page 22.

120

FUEL LIFT PUMP

The fuel lift pump is of the diaphgragm type operated by a camshaft eccentric through a drive rod.

It features an external lever for manual operation.

121

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6

Fuel system

122

123

124

125

- 58 -

Fuel feeding pump components

Components

:

1

Drive rod: - length: 32,55 ÷ 32,65 mm

2

Gasket

- measured protrusion

3

Camshaft eccentric

4

Manual priming lever

A

: 1,47 ÷ 2,07 mm

Characteristics

: when the control eccentric rotates at 1000 r.p.m. minimum delivery is

73 l/h while self-regulation pressure is 0.5 ÷ 0.7 bar.

Piston fuel lift pump (on request)

Characteristics

: when the control eccentric rotates at 1000 r.p.m. minimum delivery is

65 l/h while self-regulation pressure is 1.5 ÷ 2.5 bar.

Important

The drive rod and its protrusion do not change in relation to the diaphragm pump.

INJECTION PUMP

The injection system consists of a single-body pump with plungers featuring constant stroke and feeding one cylinder each.

The pump, mounted on the crankcase is directly operated by the camshaft.

Speed governor, extra fuel and stop device are separate from the pump

(see pages 48, 49, 50 and 78).

Injection pump for Standard and 97/68 CE engines

Components

:

1

Pump body

2

Holder-delivery valve

3

O-ring

4

Filter

5

Shim

6

Valve spring

7

Delivery valve

8

Plunger and barrel assembly

9

Gasket

10

Rack

11

Metering sleeve

12

Tappet spring

13

Upper retainer

14

Lower retainer

15

Tappet

16

Tappet roller

9LD Workshop Manual _ cod. ED0053022860 -

4° ed

_rev.

03

Injection pump for EPA engines

Components

:

1

Holder-delivery valve

2

Locking nut clamp

3

Screw

4

Valve-Spring

5

O Ring

6

Copper gasket

7

Plunger and barrel assembly

8

Pin spring

9

Rack

10

Seat spring

11

Spring tappet

12

Seat phasing

13

Ring snap

14

Tappet assembly roller

15

Pin tappet driver

16

Pump housing

17

Metering sleeve

18

Pin barrel locating

19

Copper gasket

20

Gasket fibre seal

21

Threaded cap

22

Delivery valve assembly

Fuel system

6

126

127

Plunger and Barrel Assembly

1

Barrel

2

Fuel feeding port

3

Control helix

4

Plunger

5

Retardation notch

Plunger diameter is 7.5 mm.

Important

Every plunger matches with its own barrel. For this reason they are not interchangeable.

How to check plunger and barrel for internal leakage

This operation is only indicative since pressure changes depending on the pumping speed.

Connect the delivery union with a 600 bar pressure gauge with safety valve.

Adjust rack rod at half-stroke.

Turn flywheel according to its direction of rotation so that the plunger puts the circuit under pressure.

Replace plunger if the displayed pressure is below 300 bar.

Repeat the same operation for the other plunger.

128

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Fuel system

129 130

How to check injection pump delivery valve sealing

Components:

1

Valves

2

Seat

Adjust pump rack at half-stroke.

Turn flywheel according to its direction of rotation so that the plunger puts the circuit under pressure.

During this operation the displayed pressure will gradually reach a peak followed by a sudden drop which corresponds to valve closing.

Pressure drop should be 30÷50 bar.

Replace the valve if pressure drop is below this value.

Repeat the same operation for the other plunger.

Test data for injection pump delivery

Check only maximum plunger difference by positioning rack rod according to the indicated delivery value.

131

- 60 -

Control rod max. force

Newton

0,50

9 LD 625-2 - 626-2 - 625/626 CE

Rod stroke from max deliv. point mm

10

13

0

10

R.P.M.

1500

500

150

500

Delivery mm

3

/stroke

34÷37

7÷11

70÷78

22÷26

Max. plunger difference mm

3

/stroke

3

3

--------

3

Control rod max. force

Newton

0,50

Rod stroke from max deliv. point mm

9.5

11.5

0

9.5

9 LD 625-2 EPA

R.P.M.

1500

500

150

500

Delivery mm

3

/stroke

34÷37

3÷7

60÷68

13÷18

Max. plunger difference mm

3

/stroke

3

3

--------

3

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132

Fuel system

6

How to reassemble injection pump components

After replacing the worn-out components, reassemble the pump as follows:

- Introduce sector gears into the pump body by making reference points

C

match with the

B

points on the rack.

- Fix barrels with the eccentric screws

F

on the pump body.

- Fit valves with seats, springs, fillers and delivery unions tightening them at 35 ÷ 40 Nm.

- Fit plungers by making reference points

E

match with the sector gear

D

points.

- Fix retainers and springs; lock tappet with special stop.

- Check that both plungers have the same delivery by performing the necessary measurements at the test bed; if delivery is not the same set screw

F

.

2

133

1

134

How to mount injection pump on the engine

During reassembly, make sure the adjustment rod pin

1

is correctly inserted into the opposite seat in the adjustment lever.

See “Injection advance adjustment” on page 63 for the choice of the seals

2

.

Tighten screws at 25 Nm.

Check that rack rod slides smoothly: if not, the engine may fail to start or hunt.

135

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6

Fuel system

Injection pump/mechanical speed governor timing

Loosen screw

1

Move injection pump lever

2

to maximum delivery (to the right).

Check that drive rod

3

closes the speed governor; keeping lever

2

pressed to the right the drive rod should have no clearance.

Tighten screw

1

.

136

2

1

137

138

3

(STATIC) INJECTION TIMING

Injection static advance adjustment

1

Remove rocker arm covers and high-pressure pipes.

2

Select the cylinder on which the injection static advance check will be carried out.

3

Assemble the valve lowering tool (1460.285) by fastening it to the fixing holes of the rocker arm cover screws.

4

Before tightening the tool fixing screws, make sure that the dial indicator tracer is correctly placed on the intake valve collar.

5

Place the auxiliary tank at a higher height than the one of the injection pump (~30-40 cm).

6

Connect the tank to the injection pump fuel supply hole.

7

Slowly rotate the crankshaft clockwise keeping lever

1

lowered and the valve positioned on the piston crown, until the dial indicator

2

shows the maximum measurement.

8

Set the maximum measurement dial indicator to zero which is equivalent to the compression top dead centre.

9

Assemble the advance tester

4

(serial number 1460.024) on the injection pump delivery union of the cylinder corresponding to the one on which the valve lowering tool has been previously installed.

10

Rotate the crankshaft clockwise by approximately 45°.

11

Rotate the crankshaft alternately until the fuel leaks out from tester

4

with a certain pressure.

12

Position the stop lever

3

half a stroke so that the plunger delay mark is excluded and keep the lever in this position.

139

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140

4

Fuel system

6

13

Turn the flywheel slowly and clockwise. Stop turning as soon as you notice that the fuel is moving inside tester

4

.

14

Move lever

1

again so as to lower the valve and bring it again in contact with the piston.

15

Measure the piston lowering value and bring it again in contact with the piston.

16

Convert the registered value from millimetres to degrees (see

Table "Conversion for establishing advance").

9

Engine type

L D 6 2 5 / 2

9 L D 6 2 6 / 2

9 L D

E

6

P

2 5

A

/ 2

9

C

L D

E

6 2

N

5

R

/ 2

9

C

L D

E

6 2

N

6

R

/ 2

Table “Conversion for establishing advance”

R.p.m.

Advance degrees

3

3

3

2

0

0

0

8

0

0

0

0

0

0

0

0

2 6 °

1 7 °

1 8 °

1 7 °

±

±

±

±

1

1

1

1

°

°

°

°

*

*

*

*

1

1

1 5

6

°

°

1

7 °

8 °

1

1

1

7 °

8

9

°

°

1

1

1

6

7

°

°

8 °

Piston lowering value

(mm)

2

2

2

2

4

5

6

7

°

°

°

°

4

5

5

6

.

.

.

.

9

3

7

2

4

4

6

1

1 .

9 6

2 .

2 2

2 .

5 1

2 .

8 1

2 .

5 1

2 .

8 1

3 .

1 2

2 .

2 2

2 .

5 1

2 .

8 1

* Check values.

Injection advance adjustment

If the values indicated in the table do not correspond to the detected ones, follow the operations as written below:

1)

Delayed Injection Advance: remove the shims under the pump until the detected value corresponds to the one indicated in the

Table “Conversion for establishing advance”

2)

Advanced Injection Advance: add shims under the pump until the detected value corresponds to the one indicated in the Table

“Conversion for establishing advance”.

Note:

By removing or adding a 0.1 mm shim under the pump, it is possible to advance or delay the injection by about 1°.

141

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6

Fuel system

INJECTOR

Size S Injector, only for standard engines

Components

:

1

Intake fitting

2

Nozzle holder

3

Shim

4

Spring

5

Pressure rod

6

Intermediate flange

7

Nozzle

8

Needle valve

9

Fixing flange

10

Taper pin

11

Gasket

12

System duct

13

Sump

142

Size S Nozzle, only for standard engines

Features

:

Hole number and diameter ...................4x0.28 mm.

Jet angles .............................................160°.

Needle valve elevation .........................0.20 ÷ 0.22 mm

Clean nozzle tip with a brass brush.

Check that holes are not obstructed using a mandrel with steel wìre with 0.28 mm diam.

When refitting tighten ring nut at 60 Nm.

143

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Fuel system

Size P injector, for 97/68 CE and EPA engines

Components

:

1

Injector housing

2

Intake fitting

3

Shim

4

Spring

5

Pressure rod

6

Taper pin

7

Nozzle

8

Cup

9

Needle valve

10

Sump

11

System duct

12

Overflow pipe

6

144

Size P nozzle, for 97/68 CE and EPA engines

Features

:

Hole number and diameter ............. 5 x 0.23 mm.

Jet angles ....................................... 150°.

Needle valve elevation ................... 0.200 ÷ 0.205 mm

Clean nozzle tip with a brass brush.

Check that holes are not obstructed using a mandrel with steel wìre with 0.23 mm diam.

When refitting tighten ring nut at 42 ÷ 48 Nm.

145

Injector setting

Connect the injector to a diesel injector calibration pump.

Check needle valve sealing by slowly moving hand pump until approximately 180 bar and maintain this pressure for 10 seconds.

Chek that setting pressure is 210 ÷220 bar for standard engines (245 ÷

230 bar for EPA e CE engines); make the required adjustments, if any, by modifying the adjusting shim height.

When replacing the spring, setting should be performed at a 10 bar greater pressure (255÷265 bar) to allow for bedding during operation.

Replace nozzle in case of dripping.

146

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7

ELECTRIC SYSTEM

Electric starting layout with internal alternator

Components

:

1

Alternator

2

Starting motor

3

Voltage regulator

4

Battery

5

Pressure switch

6

Oil pressure warning light

7

Key switch

8

Battery charging light

Note:

Battery, which is not supplied by

Lombardini, should feature 12 V voltage and capacity not below 70

Ah.

147

Electrical starting layout with external alternator

Components:

1

Alternator

2

Starting motor

3

Battery

4

Key switch

5

Pressure switch

6

Oil pressure warning light

7

Battery charging light

Note:

Battery, which is not supplied by

Lombardini, should feature 12 V voltage and capacity not below 70

Ah.

148

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149

Electric System

7

ALTERNATOR

Alternator - 12 V, 18A

Features a fixed armature winding mounted on the air shroud bracket.

The rotating permanent magnet inductor is located in the fan spindle.

Only the two yellow cables are at output.

Dimensions (mm):

A

= 158.80÷159.20

B

= 27.50÷27.90

Note:

Clearance between armature wìnding and inductor (air gap) must b 0.48÷0.60 mm.

Alternator battery charger curve (12 V, 18 A)

This curve is obtained at +25°C with 12.5 V battery voltage.

150

Alternator - 24 V, 6 A

Features a fixed armature winding mounted on the air shroud bracket.

The rotating permanent magnet inductor is located in the fan spindle.

There are the two yellow cables and one red cable at output.

Dimensions (mm):

A

= 158.80÷159.20

B

= 27.50÷27.90

Note:

Clearance between armature winding and inductor (air gap) should be 0.48÷0.60 mm.

151

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Electric System

Alternator battery charger curve - 24 V, 6 A

The curve was obtained at room temperature of +20°C with 25 V battery voltage.

152

153

Amp.

Alternator - 12 V, 14 A

Features a fixed armature winding mounted on the air shroud bracket.

The rotating permanent magnet inductor is located in the fan spindle.

There are the two yellow cables and one red cable at output.

Dimensions (mm):

A

= 158.80÷159.20

B

= 27.50÷27.90

Note:

Clearance between armature winding and inductor (air gap) should be 0.48÷0.60 mm.

Alternator battery charger curve standard - 12 V, 14 A

The curve was obtained at room temperature of +25°C with 12,5 V battery voltage.

154

155

- 68 -

Magnetization checking tool (Part No. 7000-9727-001)

Components:

1

Casing

2

Slider

3

Casing reference line

4

Slider reference line

Rest the tool end horizontally onto the magnetic poles.

Hold slider so that its reference line coincides with the casing reference line.

Release slider: if no attraction occurs the rotor is demagnetized, in this case replace alternator.

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1

157

Electric System

7

Checking for cable continuity

Check that stator windings have no unsoldered connections, burnt areas or grounded wìres.

Using an ohmmeter check for continuity between the red cable and the two yellow ones.

Furthermore, check that they are insulated from the ground.

Alternator, external - 12 V, 33 A

The alternator is of the claw-pole rotor type with built-in voltage regulator.

The rotating motion is conveyed by the engine through a "V" belt and sheave.

Features:

Rated voltage ......................12V

Max. current.........................33 A (at 7000 alternator r.p.m./min.).

RH direction of rotation.

Tighten the nut

1

at a torque of 70 Nm.

Alternator battery charger curve - external, 12 V, 33 A

The curve was obtained at room temperature of + 25°C.

Battery terminal voltage is 12.5 V.

The r.p.m. shown on the table refers to the engine.

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Electric System

159

VOLTAGE REGULATOR

Type LOMBARDINI, supplied by SAPRISA and DUCATI: Voltage 12 V, max. current 26A.

Connections

~

R

+

LE o o

Dimensions (mm)

Width Thickness

6.35

9.50

9.50

4.75

6.35

0.80

1.12

1.12

0.50

0.80

To avoid wrong connections 3 different sizes are supplied.

160

How to check voltage regulator for proper operation

-

Check that connections correspond to the layout.

-

Disconnect the terminal from the battery positive pole.

-

Connect a d.c. voltmeter between the two battery poles.

-

Fit an ammeter between the positive pole and the

B+

of the voltage regulator (corresponding to ref.

1

in the picture).

-

Start a couple of times until battery voltage drops below 13 V.

-

When battery voltage reaches 14.5 V the ammeter current suddenly drops down to almost zero.

-

Replace regulator if recharge current is zero with voltage below 14V.

Caution - Warning

- When the engine is running do not disconnect battery cables or remove the key from the control panel.

- Keep regulator away from heat sources since temperatures above

75°C might damage it.

- No electric welding on engine or application.

161

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163

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Electric System

Voltage regulator - 12V, 26A, with “W” terminal

“W” pole tab:

Width = 4,75 mm;

Thickness= 0,5 mm.

7

See page 70 for tag dimensions.

Voltage regulator - 12 V, 30 A

The voltage regulator is of the bridge type.

See page 70 for tag dimensions.

Voltage regulator - 12V, 30A, with “W” terminal

“W” pole tab:

Width = 4,75 mm;

Thickness= 0,5 mm.

See page 70 for tag dimensions.

- 71 -

7

Electric System

B

165

A

C

STARTING MOTOR

Important

- Made by MARELLI and BOSCH.

- Apply to their distributors for any type of repair.

Bosch starting motor type GIF - 12 V, 1.7 kW

RH direction of rotation.

A

= 29.5÷31.5 mm

B

= Ring gear plane

C

= Flange plane

Caution – Warning

Flywheel should not project from ring gear plane B.

Characteristic curves for starting motor type Bosch - 12 V, 1.7 kW

Curves are obtained at room temperature of + 20°C with 66 Ah battery.

V

= Motor terminal voltage in Volt

P

= Power in kW

C

= Torque in N/m

N

= Motor speed in r.p.m6.

J (A)

= Absorbed current in Ampere.

V

P

C

166

- 72 -

N

J(A)

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C

Electric System

Starting motor type Bosch DW (R) 12 V, 1.7 kW

RH direction of rotation.

A

= 29.5÷31.5 mm

B

= Ring gear plane

C

= Flange plane

Caution – Warning

Flywheel should not project from ring gear plane B.

B

A

167

Characteristic curves of the 24 V 1.6 kW starting motor

The curves have been measured at a 20°C temperature with an 88 Ah battery.

V =

Voltage to the motor terminals in Volt

P =

Power in kW

C =

Torque in N/m

N =

Motor speed in rpm

J (A) =

Absorbed current in Amperes.

7

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7

Electric System

168

7

3

169

4

5

2

10

9

1

8

6

1

2

3

Pre-heating glow plug

Components:

1

Sheath

2

Regulation filament

3

Heating filament

When remounting tighten at a torque of 20 Nm.

Glow plug Type

Nominal voltage

Current

1 2 V

1 2 V

4 1 A

2 4 V

2 8 V

1 3 A

Note:

The glow plug is not damaged in any way due to the prolonged activation time.

DIRECT STOP ELECTROMAGNETS

Reverse electromagnet – FIRE version

Features

:

Electromagnet type

Operating tension

Power coil absorption

Hold coil absorption

1 2 V

1 2 V

4 0 A

0 .

6 3 A

2 4 V

2 4 V

2 0 A

0 .

3 0 A

Components

:

1

Nut

2

Stud bolt

3

Flat washer

4

Screw

5

Spacer

6

Spherical joint

7

Electromagnet

8

Stop control lever

9

Axial joint

10

Stop control electromagnet support

Adjustment

:

- Carry out the adjustments by screwing and unscrewing the joints.

- Adjust the device so as to make the electromagnet get to the end of the stroke before the STOP lever reaches its limit stop after performing the operation stroke.

- When the electromagnet is excited, put the stop lever at about 1.0

– 1.5 mm from its limit stop.

- Once adjustment phase is completed, tighten nut

1

.

Important

The control cover should not present the return spring of the stop lever.

Remove the stop lever return spring without replacing the control cover if the device is applied to engines that were originally not equipped with it.

- 74 -

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170

2

1

Electric System

7

Direct stop electromagnet

Features

:

Operating tension ............................................ 12V.

Power coil absorption ...................................... 41 A.

Hold coil absorption ......................................... 0.5 A.

Setting

:

- Screw drive rod

1

to the end of the thread on the electromagnet piston.

- Excite the electromagnet and leave the stop lever in normal operation position.

- Bring drive rod 1 in contact with the stop lever and tighten lock nut

2

.

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8

SETTINGS

171

172

173

- 76 -

SPEED ADJUSTMENTS

WARNING

- Adjustments should be carried out by Lombardini authorised personnel only.

- Any tampering with the adjustment immediately makes the warranty null and void.

Idling speed setting in no-load conditions

After filling with oil and fuel, start the engine and let it warm up for 10 minutes.

Adjust idling speed at 1000÷1100 r.p.m. by turning setscrew

1

; then tighten lock nut.

Full speed setting in no-load conditions (standard)

After setting idle speed turn screw

2

and set full speed in no-load conditions at 3200 r.p.m.; then tighten lock nut.

Note:

When the engine reaches the pre-set power full speed stabilizes at 3000 r. p. m.

Not valid on EPA engines, on which it is not possible to modify the adjustment of the maximum.

INJECTION PUMP DELIVERY SETTING

Important

This adjustment must be performed with the engine connected to the dynamometric brake. Without this the regulation is approximate.

lnjection pump delivery limiting and extra fuel device

Limiting device

C

limits the injection pump maximum delivery.

It also acts as a torque setting device since spring

N

opposes the resistence of spring

M

inside the cylinder through lever

L

.

The torque setting device allows lever

L

to move over stroke

H

corresponding to 0.15÷0.25 mm.

This consequently increases injection pump delivery with torque reaching its peak value.

Note:

In generator sets and power welders, the torque setting device acts as a delivery limiter only.

It therefore does not feature spring

M

or stroke

H

.

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174

175

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Settings

8

Injection pump delivery setting with dynamometric brake

1)

Run the engine and bring it to the operating temperature.

2)

Release the flow limiter screw

C

completely (see page 175).

3)

Bring the engine to maximum rotation speed.

4)

Activate the dynamometric brake to bring the engine to the maximum speed.

5)

Check that fuel consumption is in line with the values given in the table “Specific fuel consumption”.

If it is not in line with the indicated values, reduce the dynamometric brake load.

6)

After a few operation minutes and when the engine has stabilized, slowly fasten screw

C

until the rotation speed starts decreasing.

7)

Lock screw

C

using a lock nut.

8)

Carry out the fuel consumption check again.

9)

Release the dynamometric brake and detect the rotation speed of the “stabilized” engine (maximum idle speed).

10)

Bring the engine to minimum idle speed. Carry out engine setting when the engine is "stabilized".

11)

Switch off the engine and let it cool down.

12)

Check the valve/rocker arm clearance (see "Setting valve/rocker arm clearance").

lnjection pump delivery setting without dynamometric brake

Loosen delivery limiting device

C

by 5 turns.

Bring engine to full speed in no-load conditions i.e. 3200 r.p.m.. Tighten limiting device until the engine shows a drop in r.p.m..

Unscrew limiting device

C

by 1 and ½ turns.

Tighten lock nut.

Note:

lf the engine, under full load, generates too much smoke tighten

C

; if no smoke is observed at the exhaust and the engine cannot reach its full power unscrew

C

.

- 77 -

8

Settings

Required settings (as most commonly applies)

Engine

9LD 625-2

9LD 625-2

9LD 625-2

9LD 625-2

9LD 625-2

9LD 625-2

EPA

9LD 625-2

CE

R.p.m.

1 5 0 0

3 0 0 0

3 0 0 0

3 0 0 0

1 8 0 0

1 8 0 0

1 5 0 0

Power

HP

(kW)

N

(

B

1

2

9 .

5

1

.

2

5

)

0

N B

( 1 3

1 8

.

.

5

6 )

0

N

(

A

1

1

2 .

6

1

.

5

3 )

0

N

(

B

1

1

0 .

4

8

.

8

8 )

0

N A

( 9 .

1

7

3 .

3

8 )

0

N

(

B

1

2

8 .

5

8

.

5

0 )

7

N

(

B

1

2

8 .

5

8

.

5

0 )

0

Specific fuel consumption *

Time (sec) per 100 cm

3 g/HP h

(g/kW h)

6 0 ÷ 6 3

9 0 ÷ 9 5

1 0 4 ÷ 1 1 0

1 1 0 ÷ 1 1 6

1 2 5 ÷ 1 3 2

6 0 .

5 ÷ 6 1 .

5

5 9 ÷ 6 0

1

( 2 5

9 0

8 ÷

÷ 2 0 0

2 7 2 )

1

( 2 3

7 1

3 ÷

÷ 1 8 1

2 4 6 )

1

( 2 2

6 3

3 ÷

÷ 1 7 3

2 3 5 )

1

( 2 3

7 5

9 ÷

÷ 1 8 5

2 5 2 )

1

( 2 3

6 9

0 ÷

÷ 1 7 8

2 4 3 )

1

2

9 0

5 9

÷ 1 9 4

÷ 2 6 4

1

( 2 5

9 0

8 )

The indicated specific fuel consumption refers to the period following approximately 30 working hours.

Setting the stop limit stop

1)

Remove the throttle lever cover.

1)

Completely turn lever

C

counter-clockwise and keep it in this position.

Retainer

F

should not be in contact with lever

C

.

2)

Unscrew nut

G

and bring retainer

F

in contact with lever

C

3)

Push retainer

F

so that lever

C

is moved backwards clockwise by

1.0 mm.

4)

Lock retainer

F

by screwing nut

G

Note:

In this condition, the limit stops of the injection pump adjustment rod will not be damaged by the violent impacts caused by the possible assembly of electrostop.

176

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Settings

8

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03 - 79 -

9

STORAGE

ENGINE STORAGE

-

- When the engines are not for more than 6 months, they have to be protected performing the operations described in the following pages.

- If the engine is not to be used for extensive periods, check the storage area conditions and the type of packaging and make sure that these are suitable for correct storage.

If necessary, cover the engine with a proper protective sheet.

Avoid storing the engine in direct contact with the ground, in environments that are humid and exposed to bad weather, near high voltage electric lines, etc.

Important

If, after the first 6 months, the engine is still not used, it is necessary to carry out a further measure to extend the protection period (see “Protective treatment”).

PROTECTIvE TREATMENT

1 -

Pour in the engine housing AGIP RUSTIA C protective oil up to the maximum level.

2 -

Fill up with fuel containing 10% AGIP RUSTIA NT.

3 -

Start the engine and keep it idle at minimum speed for some minutes.

4 -

Bring the engine to ¾ of the maximum speed for 5÷10 minutes.

5 -

Turn off the engine.

6 -

Empty out completely the fuel tank.

7 -

Spray SAE 10W on the exhaust and intake manifolds.

8 -

Seal the exhaust and intake ducts to prevent foreign bodies from entering.

9 -

Thoroughly clean all external parts of the engine using suitable products.

10 -

Treat non-painted parts with protective products (AGIP RUSTIA NT).

11 -

Loosen the alternator/fan belt (if present).

12 -

Cover the engine with a proper protective sheet.

Caution - Warning

In countries in which AGIP products are not available, find an equivalent product (with specifications: MIL-L-21260C).

Important

Maximum every 24 months of inactivity, the engine must be started up by repeating all "Engine Storage" operations.

- 80 -

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03

Storage

PREPARING THE ENGINE FOR OPERATION AFTER PROTECTIvE TREATMENT

9

After the storage period and before starting up the engine and preparing it for operation, you need to perform certain operations to ensure maximal efficiency conditions.

1 -

Remove the protective sheet.

2 -

Remove any sealing devices from the exhaust and intake ducts.

3 -

Use a cloth soaked in degreasing product to remove the protective treatment from the external parts.

5 -

Inject lubricating oil (no more than 2 cm3) into the intake ducts.

6 -

Adjust the alternator/fan belt tension (if present).

7

- Turn the engine manually to check the correct movement and smoothness of the mechanical parts.

8 -

Refill the tank with fresh fuel.

9 -

Make sure that the oil is up to the maximum level.

10 -

Start the engine and after some minutes bring it to ¾ of the maximum speed for 5-10 minutes.

11 -

Turn off the engine.

12 -

Remove the oil drain plug (see “Oil replacement”) and discharge the AGIP RUSTIA NT protective oil while the engine is hot.

13 -

Pour new oil (see "Table of lubricants") up to the maximum level.

14 -

Replace the filters (air, oil, fuel) with original spare parts.

Caution - Warning

Over time, a number of engine components and lubricants lose their properties, so it is important considering whether they need replacing, also based on age (see Replacement table).

Important

Maximum every 24 months of inactivity, the engine must be started up by repeating all "Engine Storage" operations.

9LD Workshop Manual _ cod. ED0053022860 -

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03 - 81 -

POSITION

Vibration-damping tank support

Connecting rod

Injection pump delivery valve union

Rocker arm cover

Center main bearing support

Intake manifold

Exhaust manifold

Air shroud

Accelerator cover

Governor control cover

Air conveyor shroud

Alternator cable clamp

High pressure fuel line clamp

Air cleaner

Hydraulic pump flange

Air conveyor shroud gasket

Head injector

Camshaft gear

Oil pump gear

Air conveyor sheet

Internal oil filter pierced plate

Breather sheet

Starting motor

Blower hub

Nippl radiator

Rocker arm shaft

Injection pump control lever pivot

Speed governor external control lever pivot

External stop control lever pivot

Governor spring lower lever pivot

Gear cover plate

Engine mounting foot

Fuel feeding pump

Injection pump

Oil pump

Nozzle holder

Oil pan

Oil pressure switch

Starter motor fixing stud

Fuel lift pump fixing stud

Cylinder head fixing stud

Cooling fan guard

Starting pulley

Fuel filter union

Fuel lift pump union

High pressure fuel line union

Fuel bleeding line union

Voltage regulator

R.p.m. counter driving gear

Main bearing support, gear case side

Main bearing support, flywheel side

Center main bearing support

Air conveyor support

Hydraulic pump gear support

Injection pump control lever support

Governor lever support (camshaft seal)

Governor fork support

- 82 -

10

TORQUE SPECIFICATIONS AND USE OF SEALANT

Table of tightening torques for the main components

Diam. and pitch

( mm )

-

8x1.0

18x1.5

8x1.25

8x1.25

8x1.25

8x1.25

6x1.0

6x1.0

6x1.0

8x1.25

6x1.0

5x0.8

8x1.25

Torque

( Nm )

10

10

20

10

5

25

25

25

25

6

-

40

40

20

Sealant

Loctite 270

8x1.25

10x1.5

8x1.25

8x1.25

8x1.25

6x1.0

8x1.25

12x1.5

10x1.5

8x1.25

10x1.5

6x1.0

10x1.5

14x1.5

10x1.0

12x1.5

8x1.25

-

6x1.0

10x1.5

10x1.5

6x1.0

6x1.0

6x1.0

10x1.5

14x1.5

14x1.5

8x1.25

8x1.25

8x1.25

8x1.25

8x1.25

8x1.0

8x1.25

5x0.8

8x1.25

8x1.25

10x1.5

8x1.25

8x1.25

8x1.25

8x1.25

8x1.25

25

12

25

10

20

15

10

45

40

25

25

20

10

30

25

12

8÷10

25

20

25

25

25

5

30

30

30

10

10

25

40

40

25

15

10

10

10

45

160

10

60

35

10

Loctite 495

Loctite 270

Loctite 270

Loctite 242

Loctite 270

Loctite 270

Loctite 270

9LD Workshop Manual _ cod. ED0053022860 -

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03

Fuel tank bracket

Alternator stator

Crankase lubrification plug

POSITION

Oil drain plug

Cylinder head

Blower

Cooling fan hub fixing screw

Flywheel

Torque specifications and use of sealant

10

Diam. and pitch

( mm )

8x1.25

5x0.8

8x1.25

14x1.5

10x1.5

6x1.0

16x1.5

20x1.5

Torque

( Nm )

30

7

15

40

55

10

160

300

Sealant

Loctite 242

Loctite 270

Loctite 270

9LD Workshop Manual _ cod. ED0053022860 -

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10

Torque specifications and use of sealant

Diameter

M12

M14

M16

M18

M20

M22

M24

M27

M30

M3

M4

M5

M6

M8

M10

Table of tightening torques for standard screws (coarse thread)

4.6

4.8

5.6

Resistance class (R)

5.8

6.8

Quality/

Dimensions

154

206

266

394

32

51

79

109

544

Nm

0,5

1,1

2,3

3,8

9,4

18

R>400N/mm

2

205

275

355

525

43

68

105

145

725

Nm

0,7

1,5

13

25

3

5

R>500N/mm

2

193

260

333

500

40

63

98

135

680

Nm

0,6

1,4

2,8

4,7

12

23

256

344

444

656

54

84

131

181

906

Nm

0,9

1,8

3,8

6,3

16

31

8.8

10.9

12.9

R>600N/mm

2

308

413

533

788

65

101

158

218

1088

Nm

1

2,2

4,5

7,5

19

37

R>800N/mm

2

86

135

210

290

410

550

710

1050

1450

Nm

1,4

2,9

6

10

25

49

R>1000N/mm

2

120

190

295

405

580

780

1000

1500

2000

Nm

1,9

4,1

8,5

14

35

69

R>1200N/mm

2

145

230

355

485

690

930

1200

1800

2400

Nm

2,3

4,9

10

17

41

83

Diameter

M 8x1

M 10x1

M 10x1,25

M 12x1,25

M 12x1,5

M 14x1,5

M 16x1,5

M 18x1,5

M 18x2

M 20x1,5

M 20x2

M 22x1,5

M 24x2

M 27x2

M 30x2

Table of tightening torques for standard screws (fine thread)

4.6

4.8

5.6

Resistance class (R)

5.8

6.8

Quality/

Dimensions

164

229

293

431

84

122

117

173

600

Nm

10

21

20

36

38

56

R>400N/mm

2

Nm

14

28

26

48

45

75

113

163

157

230

218

305

390

575

800

R>500N/mm

2

287

367

533

750

153

147

213

204

45

42

70

105

Nm

13

26

24

203

196

288

273

381

488

719

1000

59

56

94

141

Nm

17

35

33

8.8

10.9

12.9

R>600N/mm

2

244

235

345

327

458

585

863

1200

71

68

113

169

Nm

20

42

39

R>800N/mm

2

325

313

460

436

610

780

1150

1600

95

90

150

225

Nm

27

56

52

R>1000N/mm

2

460

440

640

615

860

1100

1600

2250

135

125

210

315

Nm

38

79

73

R>1200N/mm

2

380

550

530

770

740

1050

1300

1950

2700

Nm

45

95

88

160

150

250

- 84 -

9LD Workshop Manual _ cod. ED0053022860 -

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SPECIAL TOOLS

11

1

2

SPECIAL TOOLS

Special tools and equipment for maintenance

DESCIPTION

3

Valve lowering tool for static injection timing check

1

Spacers, h=40mm

2

Dial gauge indicator

3

Dial gauge extension

Static timing tool

Part N°.

1460 - 285

1460 - 024

Tool for valve stem O-ring assembly

1460 - 047

Flywheel puller

1460 - 119

Timing control gear extractor fork

7560-4000- 052

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03 - 85 -

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03 - 87 -

9 LD Engine Series

cod. ED0053022860

La Lombardini si riserva il diritto di modificare in qualunque momento i dati contenuti in questa pubblicazione.

Lombardini se rèserve le droit de modifier, à n'importe quel moment, les données reportées dans cette publication.

Data reported in this issue can be modified at any time by Lombardini.

Lombardini behält sich alle Rechte vor, diese Angabe jederzeit zu verändern.

La Lombardini se reserva el derecho de modificar sin previo aviso los datos de esta publicación.

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